3D Lamination Shaping Condition Determination for Defect Reduction
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Solution Overview
Problem
Three-dimensional additive manufacturing methods face challenges with internal defects such as micro-voids and increased surface roughness, particularly in inclined parts, which reduce fatigue life and require longer manufacturing times to optimize, thereby increasing costs.
Innovation Solution
A method that identifies specific parts within a three-dimensional object requiring tailored manufacturing conditions, applying enhanced beam irradiation and scanning parameters only to these critical areas to improve internal defect dimensions and surface roughness without extending overall manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manufacturing conditions are optimized by increasing beam irradiation次数, decreasing scanning speed, or decreasing scanning pitch, then internal defects and surface roughness are reduced, but manufacturing time increases
Solution Approach 1:
The patent applies different manufacturing conditions to different regions of the three-dimensional object based on their specific characteristics. Critical regions (such as inclined side parts, overhang parts, and parts with small radii of curvature) are identified and assigned optimized manufacturing conditions (increased beam irradiation次数, decreased scanning speed, decreased scanning pitch), while non-critical regions use standard conditions. This resolves the contradiction by localizing quality enhancement to where it is most needed, avoiding unnecessary time consumption in regions where high precision is not critical.
Solution Approach 2:
The patent segments the three-dimensional object into multiple regions based on geometric characteristics and fatigue life requirements. By dividing the object into critical and non-critical regions, the manufacturing process can be optimized locally rather than uniformly across the entire object. This segmentation allows the manufacturing time to be extended only for critical regions while maintaining standard speeds for non-critical regions, thus resolving the time-quality contradiction.
2Reliability
If manufacturing conditions are optimized for the entire three-dimensional object, then fatigue life is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements local quality enhancement by identifying and treating only critical regions that significantly affect fatigue life. By applying optimized manufacturing conditions (which increase manufacturing cost) only to these critical regions rather than the entire object, the patent achieves improved fatigue life while minimizing the increase in manufacturing cost. This resolves the contradiction by making cost investment proportional to the actual fatigue life benefit.
Solution Approach 2:
The patent segments the object into critical and non-critical regions based on their contribution to overall fatigue life. Critical regions (such as inclined side parts and overhang parts) receive enhanced manufacturing conditions, while non-critical regions use standard conditions. This segmentation strategy optimizes the balance between fatigue life improvement and manufacturing cost by concentrating resources where they provide the most benefit.
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 allows for the creation of three-dimensional objects with enhanced fatigue life without increasing production time, optimizing internal defect dimensions and surface roughness, thus improving product quality and reducing costs.
Implementation Method 1
a portion corresponding to a build part is irradiated with beam (e.g., laser beam or electron beam) to selectively melt and solidify the powder layer
Implementation Method 2
selectively melt and solidify the powder layer
Data Source
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AI summary
A three-dimensional lamination shaping method for laminating shaping material to shape a three-dimensionally shaped object on the basis of design data of the three-dimensionally shaped object is provided with: a specific-part identification step of identifying a specific part partially included in the three-dimensionally shaped object on the basis of the design data; a specific-part shaping condition determination step of determining whether a specific shaping condition different from a normal shaping condition for shaping a normal part of the three-dimensionally shaped object other than the specific part is applied to shaping of the specific part to determine a shaping condition of the specific part; and a shaping condition setting transmission step of transmitting a shaping condition setting in which the normal part other than the specific part is shaped under the normal shaping condition and the specific part is shaped under the shaping condition determined in the specific-part shaping condition determination step.