Hybrid Additive Manufacturing Heating System for Bonding Control

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Solution Overview

Problem

Additive manufacturing machines face challenges in achieving robust bonding and consistent temperature control across varying part geometries due to the limitations of unfocused energy sources, which can result in weak features, defects, and increased processing time, especially when using powdered build materials.

Innovation Solution

The implementation of a hybrid system that combines both unfocused and focused energy sources within an additive manufacturing machine, where the unfocused energy sources provide general heating and the focused energy sources offer precise heating to specific areas, allowing for controlled temperature management and improved bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If unfocused energy sources are used for heating build material, then general heating coverage is improved, but temperature control precision and bonding quality deteriorate

Engineering Contradiction:

Improveheating coverage areaVSAvoidtemperature control precision

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The heating system is segmented into two distinct components: unfocused energy sources (heating lamps) for general area heating and focused energy sources (lasers) for precise localized heating. This segmentation allows each component to perform its specialized function optimally - the unfocused sources provide broad thermal coverage while the focused sources deliver precise temperature control for bonding critical features.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the build platform receive different heating treatments. Critical areas requiring precise temperature control (such as small features and perimeters) receive focused laser heating, while non-critical areas receive general unfocused heating. This local quality approach ensures that temperature precision is applied exactly where needed without compromising overall heating efficiency.

Inventive Principle:

Principle #3Local quality

2Productivity

If unfocused energy sources are used for heating, then processing speed is improved, but bonding quality and feature strength deteriorate

Engineering Contradiction:

Improveprocessing speedVSAvoidbonding quality

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The processing system is divided into two functional segments: unfocused energy sources that rapidly heat large areas to maintain processing speed, and focused energy sources that provide precise localized heating to ensure proper bonding quality. This segmentation allows the system to achieve both high productivity through efficient bulk heating and high strength through precise bond-line heating.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The unfocused energy sources perform preliminary heating of the build material and surrounding areas before the focused energy sources apply precise heating for bonding. This preliminary action raises the baseline temperature quickly, reducing the total processing time required, while the subsequent focused heating ensures proper bonding quality without requiring prolonged exposure.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If focused energy sources are used for precise heating, then temperature control precision is improved, but processing time increases

Engineering Contradiction:

Improvetemperature control precisionVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The heating system is segmented so that unfocused energy sources handle the time-consuming bulk heating task, while focused energy sources handle only the small critical areas requiring precision. This segmentation dramatically reduces the total time required for precise heating compared to using focused sources alone, as the majority of the build area is heated efficiently by the unfocused sources.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The unfocused energy sources apply excessive heating to areas beyond the immediate build features, heating the surrounding build material and platform. While this appears wasteful, it actually reduces processing time by ensuring that all areas requiring subsequent precise heating are already at an elevated temperature, reducing the duration needed for the focused heating step.

Inventive Principle:

Principle #16Partial or excessive action

4Reliability

If hybrid energy sources are used, then equipment complexity increases, but overall system performance improves

Engineering Contradiction:

Improvebonding reliabilityVSAvoidenergy source configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system merges two different energy source technologies (unfocused heating lamps and focused lasers) into a single integrated heating system. This combining allows the system to leverage the advantages of both approaches - the cost-effectiveness and broad coverage of unfocused sources and the precision and control of focused sources - resulting in improved bonding reliability despite the increased configuration complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hybrid energy source system provides multi-functionality by capable of performing both broad area heating and precise localized heating with a single integrated system. This universality allows the equipment to handle a wide variety of build scenarios and part geometries, improving reliability across different applications while the control system manages the complexity of coordinating multiple energy sources.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This hybrid approach enhances the quality of 3D parts by ensuring robust bonding and reducing defects, particularly for small features and perimeters, while maintaining efficient processing times by selectively using focused energy for targeted areas.

Implementation Method 1

an unfocused energy source may be used to irradiate a layer of build material 110 with the intention of heating portions of the layer of build material 110, for example, portions on which a liquid agent has been deposited, to a temperature above a melting temperature of the build material

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Thermal Radiation

Implementation Method 2

a focused energy source 150 (such as a laser) can be used to direct energy towards a target portion 153 of the layer of build material 110

Methodology Applied

Scientific EffectFocused electromagnetic energy heating: Laser

Implementation Method 3

a fusing agent with a target pattern can be deposited on the layer of build material 110... the fusing agent absorbs heat energy emitted from an energy source used in the additive manufacturing process

Methodology Applied

Scientific EffectHeat absorption: Absorption (EM radiation)

Data Source

PatentUS20220184889A1Additive manufacturing machines comprising focused and unfocused energy sources

Publication Date: 2022.06.16 PERIDOT PRINT LLC

AI summary

In some examples, an additive manufacturing machine includes an unfocused energy source to heat portions of a layer of build material as the unfocused energy source moves across the layer of build material during a build operation of a three-dimensional (3D) object. A focused energy source is controllable to selectively direct focused energy on the layer of build material during the build operation.