Interlace Path Optimization for Multi-Beam Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for improved methods to define an interlace path for additive manufacturing machines that utilize multiple energy beams, as the location of the interlace path significantly impacts irradiation, object, and production parameters, requiring a balance between productivity and quality.
Innovation Solution
The use of a route-finding algorithm to determine an interlace path across an interlace region of an object slice, which assigns contour zones to energy beams and defines their interaction, optimizing parameters such as energy density, melt pool size, and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an interlace path is positioned to maximize productivity, then production speed increases, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies parameter changes by using a route-finding algorithm to dynamically determine the optimal interlace path position based on multiple parameters including energy density, melt pool size, and processing time. The algorithm evaluates different path locations and selects the one that achieves the best balance between productivity and quality by adjusting these parameters systematically.
Solution Approach 2:
The patent applies local quality by allowing different regions of the build plane to have different interlace path positions optimized for their specific requirements. The route-finding algorithm evaluates local conditions at various locations and determines the optimal interlace path position for each region, enabling some areas to prioritize productivity while others prioritize quality.
2Manufacturing precision
If an interlace path is positioned to maximize quality, then manufacturing precision improves, but productivity deteriorates
Solution Approach 1:
The patent uses parameter changes by systematically evaluating how different interlace path positions affect energy density, melt pool characteristics, and processing time. The route-finding algorithm adjusts these parameters to find the optimal position that achieves high quality while minimizing the negative impact on productivity.
Solution Approach 2:
The patent applies dynamics by making the interlace path position adaptive rather than fixed. The route-finding algorithm dynamically determines the optimal position based on real-time evaluation of multiple parameters, allowing the system to adjust the interlace path location to balance quality and productivity requirements.
3Productivity
If multiple energy beams are used to increase productivity, then production speed increases, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the build plane into distinct regions assigned to different energy beams. The route-finding algorithm determines optimal interlace paths for each beam's assigned region, allowing independent optimization of each beam's trajectory while maintaining overall system coordination, thus managing complexity through systematic division.
Solution Approach 2:
The patent applies universality by using a single route-finding algorithm that can optimize interlace paths for multiple energy beams simultaneously. The algorithm serves as a universal tool that handles the coordination complexity of multiple beams through a unified approach, rather than requiring separate control mechanisms for each beam.
Data Source
AI summary
A method of additively manufacturing an object may include defining an interlace path for a plurality of energy beams from an energy beam system based at least in part on a route-finding algorithm. The interlace path may delineate a first contour zone of a build plane assigned to a first one of the plurality of energy beams from a second contour zone of the build plane assigned to a second one of the plurality of energy beams. An exemplary method may additionally or alternatively include outputting a control command based at least in part on the interlace path. The control command may be configured to cause the energy beam system to irradiate a layer of a powder bed with the plurality of energy beams.