Inclined Wall Bead Stacking in Laser Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing techniques, such as directed energy deposition, face challenges in forming inclined walls due to gravity-induced bending of melted metal beads, requiring strict control of beam irradiation positions.
Innovation Solution
An additive manufacturing apparatus that includes a material supply unit, an emission unit for melting the build material, and a control device to manage the formation of inclined shapes by stacking beads in a manner where the upper bead layer is formed with partial contact only with the side surface of the lower bead layer, preventing significant downward bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional directed energy deposition is used to form inclined walls, then material can be deposited efficiently, but the melted metal bead bends downward due to gravity when beam irradiation position deviates, causing loss of shape
Solution Approach 1:
The bead layer is segmented into multiple individual beads arranged in a specific pattern. The lower bead layer consists of multiple beads, and the upper bead layer is formed by depositing beads on specific portions of the lower bead layer, with some beads having partial contact only with side surfaces. This segmentation allows gravity to be managed at the individual bead level while maintaining overall shape accuracy.
Solution Approach 2:
Different regions of the bead layer have different contact characteristics. Some beads in the upper layer have full contact with the lower layer, while other beads have partial contact only with side surfaces of lower beads. This local variation in contact quality enables the formation of inclined walls without requiring strict beam irradiation position control throughout the entire structure.
2Manufacturing precision
If strict control of beam irradiation position is implemented to prevent bead bending, then shape accuracy can be maintained, but the complexity and difficulty of the process increases
Solution Approach 1:
The bead deposition pattern is designed to self-support against gravity through its geometric configuration. By arranging beads so that upper beads contact lower beads at specific locations (with some having partial contact only with side surfaces), the structure inherently resists gravitational deformation without requiring active beam position correction systems.
3Loss of substance
If conventional bead stacking is used, then material utilization is efficient, but inclined walls cannot be formed easily due to gravity-induced deformation
Solution Approach 1:
The bead arrangement transitions from conventional two-dimensional stacking to a three-dimensional configuration where beads are positioned at different heights and lateral positions. The upper bead layer is formed by depositing beads on specific portions of the lower bead layer, with some beads having partial contact only with side surfaces, creating a stable inclined structure that resists gravitational deformation.
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
Enables the easy and precise formation of inclined walls without the need for strict beam irradiation position control, reducing material waste and improving shape accuracy.
Implementation Method 1
an emission unit to emit a laser beam to the machining area to melt the build material
Implementation Method 2
the technology of foregoing Patent Literature 1 allows a melted metal bead to bend downward due to action of gravity upon occurrence of a slightest deviation of the beam irradiation position
Data Source
AI summary
An additive manufacturing apparatus forming an inclined shaped object on an additive target surface of a base substrate, includes a material supply unit supplying the build material to a machining area of the additive target surface, an emission unit emitting laser beam to the machining area to melt the build material, and a control device controlling formation of the inclined shaped object by controlling the material supply unit and the emission unit. The control device causes a first inclination bead to be formed on a top surface of a lower inclination bead layer, and then causes a second inclination bead in contact with the top surface of the lower inclination bead layer and a side surface of the first inclination bead, to be formed at a position where part of the bottom surface of the second inclination bead has no contact with the lower inclination bead layer.