Irradiation System Control for Additive Manufacturing
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Solution Overview
Problem
Existing methods for producing three-dimensional work pieces by selective laser melting or laser sintering face challenges in achieving high-quality construction across multiple irradiation areas without interference and ensuring consistent quality and reliability, especially when dealing with large or complex geometries.
Innovation Solution
A method and device that control an irradiation system with multiple units, defining distinct irradiation areas and an overlap area, allowing each unit to operate independently and adjust radiation patterns to split sections of the pattern or contour that span multiple areas, ensuring accurate and reliable irradiation by assigning portions to specific units and optimizing radiation energy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple irradiation units are used to irradiate large three-dimensional work pieces, then productivity and coverage area are improved, but interference between irradiation units occurs leading to quality issues
Solution Approach 1:
The patent divides the work piece construction area into multiple distinct irradiation areas, each assigned to a specific irradiation unit. This segmentation allows each unit to operate independently within its designated area, eliminating interference between units while maintaining high productivity through parallel processing of multiple areas simultaneously.
Solution Approach 2:
The patent introduces a control device as an intermediary that coordinates the operation of multiple irradiation units. The control device manages the timing and parameters of each unit to prevent interference, ensuring that adjacent irradiation areas do not receive conflicting radiation that would compromise quality consistency.
2Reliability
If irradiation areas are defined for each unit, then interference is minimized, but the complexity of controlling multiple units increases
Solution Approach 1:
The control device is designed with multi-functionality, serving as both the coordinator for multiple irradiation units and the manager of construction parameters. This universal control system consolidates what would otherwise be multiple separate control systems, reducing overall complexity while maintaining the ability to define and manage multiple irradiation areas effectively.
3Manufacturing precision
If radiation patterns are adjusted for each irradiation area, then manufacturing precision is improved, but the time required for pattern adjustment increases
Solution Approach 1:
The control device pre-defines multiple irradiation areas with their respective radiation patterns before the additive manufacturing process begins. By preparing these patterns in advance, the system eliminates the need for time-consuming adjustments during production, maintaining high irradiation accuracy while minimizing setup time through parallel preparation of all irradiation areas.
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 approach enables the production of high-quality three-dimensional work pieces by minimizing interference between irradiation units, ensuring consistent quality across large or complex geometries, and reducing excessive radiation energy application, thus enhancing the reliability and efficiency of the additive layer construction process.
Implementation Method 1
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 2
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 3
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Data Source
AI summary
A method for controlling an irradiation system (20) for use in an apparatus (10) for producing a three-dimensional work piece and comprising a plurality of irradiation units (22a, 22b) a first and a second irradiation area (18a, 18b) as well as an overlap area (26) arranged between the first and the second irradiation area (18a, 18b) is defined on a surface of a carrier (16) adapted to receive a layer of raw material powder. A first irradiation area (22a) of the irradiation system (20) is assigned to the first irradiation area (18a) and the overlap area (26), and a second irradiation unit (22b) of the irradiation system (20) is assigned to the second irradiation area (18b) and the overlap area (26). If it is determined that a section (S) or a radiation pattern according to which radiation beams (24a, 24b) emitted by the irradiation units (22a, 22b) of the irradiation system (20) are guided over the layer of raw material powder received on the carrier (16) and/or a contour (C) of the three-dimensional work piece to be produced extend(s) into the first and the second irradiation area (18a, 18b) defined on the surface of the carrier (16), said section (S) of the radiation pattern and/or said contour (C), in a splitting region of the section (S) of the radiation pattern and/or the contour (C) which is located in the overlap area (26) arranged between the first and the second irradiation area (18a, 18b), is split into a first portion (S1, C1) and a second portion (S2, C2). The first portion (S1, C1) of said section (S) of the radiation pattern and/or said contour (C) is assigned to the first irradiation unit (22a) and the second portion (S2, C2) of said section (S) of the radiation pattern and/or said contour (C) is assigned to the second irradiation unit (22b).