Laser Ablation Tool Paths for Complex Structural Surfaces
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Solution Overview
Problem
Current laser ablation techniques for structural parts, such as aircraft components, are not precise enough to ensure effective paint adhesion, requiring multiple passes and manual re-positioning due to complex surface geometries, which is time-consuming and labor-intensive.
Innovation Solution
A digital model of the structural part is divided into tiles, and discrete tool paths with optimized laser orientations are determined to maximize average laser intensity across each surface region, allowing for efficient and precise ablation without the need for multiple passes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current laser ablation techniques are used on complex surface geometries, then ablation speed is improved, but manufacturing precision deteriorates because the laser cannot maintain effective intensity across all surface regions
Solution Approach 1:
The digital model of the structural part is divided into multiple tiles, each representing a specific surface region. This segmentation allows the system to calculate and optimize laser parameters independently for each tile, ensuring precise ablation control across complex geometries while maintaining high productivity through automated processing.
Solution Approach 2:
The system determines discrete tool paths and laser orientations specific to each tile based on its local surface characteristics. By adapting laser parameters locally to match the specific geometry of each region, the system achieves consistent ablation quality across the entire part without requiring multiple manual passes.
2Manufacturing precision
If manual sanding is used to prepare surfaces, then manufacturing precision is improved for paint adhesion, but productivity deteriorates due to time-consuming labor-intensive processes
Solution Approach 1:
The system replaces manual mechanical sanding with automated laser ablation controlled by computer-generated tool paths. This substitution eliminates labor-intensive manual operations while maintaining precise surface preparation quality through algorithmically optimized laser parameters adapted to each surface region.
3Device complexity
If laser orientation is not optimized for each surface region, then device complexity is reduced, but manufacturing precision deteriorates because paint adhesion requirements are not met
Solution Approach 1:
The system performs preliminary calculations to determine optimal laser orientations and discrete tool paths for each tile before actual ablation begins. By pre-computing the ideal laser configuration for every surface region based on the digital model, the system achieves high manufacturing precision without requiring complex real-time adjustments during processing.
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 precise laser ablation that enhances paint adhesion characteristics by optimizing laser orientation and position, reducing the need for manual re-positioning and multiple passes, thus improving efficiency and effectiveness.
Implementation Method 1
laser ablation of a surface of a structural part
Data Source
AI summary
An apparatus, method and computer-readable storage medium are provided for laser ablation of a structural part. The method includes accessing a digital model of the structural part, and tiling the digital model into tiles that correspond to respective regions of the structural part. The method includes determining discrete tool paths of a machine tool for respective ones of the tiles for laser ablation of the respective regions of the structural part. And the method includes generating instructions for the machine tool to perform the laser ablation of the structural part according to the discrete tool paths.