Laser Additive Manufacturing Temperature Control via Light Guide
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Solution Overview
Problem
Current generative manufacturing methods, such as selective laser melting, face inefficiencies due to the need for all laser scanners to complete their areas before applying a new powder layer, limiting production speed and complexity of devices required for precise temperature control.
Innovation Solution
A method and device that use laser radiation to heat and partially melt powder layers, with temperature information detected and used to adjust laser intensity, allowing for simultaneous irradiation by multiple laser sources and continuous powder application, reducing thermal gradients and enabling faster, more efficient component production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser scanner units are used to produce areas of components simultaneously, then production speed is significantly increased, but all scanners must complete their assigned areas before a new powder layer can be applied, causing idle time and reducing overall efficiency
Solution Approach 1:
The patent implements continuous powder layer application during laser irradiation by coordinating the powder delivery system with multiple laser scanners. The powder layer is applied continuously across the build area while lasers are actively melting powder, eliminating idle time between layers and maintaining continuous productive action throughout the manufacturing process.
Solution Approach 2:
The patent applies powder layers in advance during the laser irradiation process rather than waiting for completion. The powder delivery system is positioned to apply subsequent layers ahead of time while previous layers are being processed by lasers, ensuring material readiness without interrupting the melting operation.
2Productivity
If laser intensity is increased to improve production speed, then melting efficiency increases, but thermal gradients and distortion increase, reducing component quality
Solution Approach 1:
The patent employs independent intensity control for each laser scanner unit, allowing different regions of the build area to receive customized laser power levels. This enables optimization of melting efficiency in specific areas while controlling thermal gradients in sensitive regions, achieving local quality variations that balance productivity and precision.
Solution Approach 2:
The patent dynamically adjusts laser intensity parameters during the manufacturing process based on real-time temperature feedback and process conditions. By varying power levels, scan speeds, and pulse durations, the system optimizes melting efficiency while maintaining thermal gradients within acceptable limits to prevent excessive distortion.
3Manufacturing precision
If temperature control mechanisms are added to reduce thermal distortion, then component quality improves, but device complexity increases
Solution Approach 1:
The patent incorporates temperature sensors that continuously monitor the build area during laser irradiation. The detected temperature information is fed back to the control system, which automatically adjusts laser intensity parameters to maintain optimal temperature ranges, reducing thermal distortion through closed-loop control without requiring complex mechanical intervention systems.
Solution Approach 2:
The patent enables the manufacturing system to self-regulate temperature by using real-time temperature data to automatically adjust laser parameters. The system monitors its own thermal state and makes corrective adjustments without external intervention, simplifying the overall control architecture while maintaining precision.
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 faster, cost-effective production of complex components with reduced thermal distortion and stress, improving the quality and efficiency of generative manufacturing by allowing continuous layer production and precise temperature control.
Implementation Method 1
A powder of a material is irradiated by means of laser radiation so that it is heated and at least partially melted and the molten material solidifies
Implementation Method 2
irradiated by means of laser radiation so that it is heated and at least partially melted
Implementation Method 3
Information relating to the temperature of the material irradiated and/or to be irradiated, in particular thermal radiation, is detected and used for influencing the laser intensity
Data Source
AI summary
The invention relates to a method for the generative production of at least one component, a device for performing the method and a motor vehicle, in particular a passenger car. In a method for the generative production of at least one component, a powder of a material is irradiated by means of laser radiation so that it is heated and at least partially melted and the molten material solidifies in order to at least partially form the component. Information relating to the temperature of the material irradiated and/or to be irradiated, in particular thermal radiation, is detected and used for influencing the laser intensity. The laser radiation is conducted at least in sections by means of a light guide to the material and the information relating to the temperature is transmitted in the inner region of the light guide for the purpose of its detection.