Additive Manufacturing Irradiation Array Energy Uniformity
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Solution Overview
Problem
Existing additively manufacturing apparatuses with irradiation devices featuring multiple irradiation elements as an array face challenges in ensuring uniform energy input into the build material due to fixed spatial relations between elements, leading to variations in energy deposition along energy beam paths.
Innovation Solution
The apparatus incorporates a control unit to manage the ratio of energy inputs and spot sizes of energy beams emitted by multiple irradiation elements, allowing for adjustment based on parameters like path length differences and curvature, ensuring homogeneous energy distribution across the build plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple irradiation elements are arranged as a fixed array, then the device can irradiate multiple areas simultaneously improving productivity, but the fixed spatial relation causes non-uniform energy input along different beam paths
Solution Approach 1:
The patent makes the irradiation array movable relative to the build plane, transforming it from a static to a dynamic system. This allows the array to be repositioned during the additive manufacturing process to compensate for path length differences and curvature effects, ensuring uniform energy distribution across different build areas while maintaining the productivity benefit of simultaneous multi-area irradiation
Solution Approach 2:
The patent dynamically adjusts operational parameters including the position of the irradiation array, beam power levels, and scanning speeds for different irradiation elements. By changing these parameters in real-time based on the specific geometry and position being irradiated, the system compensates for path length variations and maintains consistent energy input per unit area across the entire build plane
2Manufacturing precision
If the irradiation array is moved relative to the build plane, then uniform energy distribution can be achieved, but the system complexity increases
Solution Approach 1:
The movable irradiation array system serves multiple functions: it enables uniform energy distribution across different build areas, allows flexibility in irradiating complex geometries, and maintains the capability for simultaneous multi-area processing. This multi-functionality justifies the added motion control complexity by providing versatile manufacturing capabilities
Solution Approach 2:
The system incorporates control mechanisms that monitor and adjust the position and operational parameters of the irradiation array in real-time. This feedback control ensures that the added complexity of the movable system is managed effectively, maintaining precision while adapting to various build geometries and energy distribution requirements
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 solution enables uniform energy input and distribution, compensating for path length variations and curvature effects, thereby enhancing the homogeneity of energy depletion in the build material, regardless of the irradiation element's position in the array.
Implementation Method 1
each emitting an energy beam, in particular a laser beam or an electron beam
Implementation Method 2
a selective laser sintering apparatus, a selective laser melting apparatus or a selective electron beam melting apparatus
Implementation Method 3
successive selective layerwise consolidation of layers of a powdered build material
Data Source
Figure 1
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AI summary
Apparatus (1, 32) for additively manufacturing of three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an irradiation device (3) comprising at least two irradiation elements (4 - 8) arranged as an irradiation array (9), in particular on at least one common irradiation element carrier (10), wherein each irradiation element (4 - 8) is adapted to emit an energy beam (11 - 15) guidable or guided along an, in particular at least partially curved, energy beam path (17 - 21) in the build plane (16), wherein the irradiation array (9) is moveable relative to the build plane (16), wherein a control unit (22) is provided that is adapted to control a ratio of at least two energy inputs into at least two energy beam paths (17 - 21) of at least two energy beams (11 -15) and/or a ratio of spot sizes of at least two energy beams (11 -15) emitted by at least two irradiation elements (4 - 8).