Laser Diode Array Layout for Uniform Powder Bed Fusion Heating
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in achieving uniform power density and control over melt pool geometry during powder bed fusion processes, leading to variability in build quality and processing speed.
Innovation Solution
The use of a plurality of laser diode arrays configured to emit energy beams in an alternating pattern with a lower intensity and power density, allowing for increased resolution and improved temperature control, which reduces thermal interactions between adjacent beam spots and enhances the uniformity and controllability of the energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single high-intensity laser beam is used for powder bed fusion, then processing speed is improved, but uniformity of power density and control over melt pool geometry deteriorate
Solution Approach 1:
The single high-intensity laser beam is segmented into multiple lower-intensity beams arranged in arrays. These multiple beams work in concert to deliver the total required energy while distributing the power density more uniformly across the build area, thereby maintaining processing speed while improving uniformity and control.
Solution Approach 2:
The patent transitions from a single-point irradiation approach to a multi-point distributed beam arrangement. By organizing beams in two-dimensional arrays with specific spacing and overlap patterns, the system achieves better spatial distribution of energy, improving power density uniformity while maintaining overall processing efficiency.
2Productivity
If higher power density is used to increase processing speed, then productivity is improved, but thermal interactions between adjacent beam spots increase
Solution Approach 1:
The total energy delivery is segmented across multiple beams with lower individual power densities. This segmentation reduces the thermal influence zone of each beam, minimizing unwanted thermal interactions between adjacent melt pools while maintaining overall processing speed through the combined effect of multiple beams.
Solution Approach 2:
Each individual beam in the array is configured with optimized local power density tailored to its specific position and function. This allows precise control over thermal interactions in different regions of the build area, reducing harmful thermal effects while maintaining productivity.
3Manufacturing precision
If lower intensity beams are used to reduce thermal interactions, then manufacturing precision is improved, but processing speed deteriorates
Solution Approach 1:
Multiple lower-intensity beams are merged in spatial and temporal coordination to achieve the cumulative energy input required for efficient processing. This merging allows each beam to maintain low enough intensity for precise control while the combined effect delivers sufficient total power for high processing speed.
Solution Approach 2:
The multiple beams operate in a coordinated continuous manner, with overlapping scan patterns and synchronized timing, ensuring that the useful heating action is maintained continuously across the build area. This eliminates idle time and maintains high productivity despite the use of lower-intensity individual beams.
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 results in improved build quality, uniformity, and increased processing speeds while maintaining control over the melt pool geometry, enabling the production of three-dimensional objects with smaller features and better surface properties.
Implementation Method 1
an energy beam generated by an irradiation device is directed onto a powder bed to melt and/or sinter sequential layers of powder material
Implementation Method 2
a plurality of laser diode arrays configured to emit a plurality of energy beams
Implementation Method 3
an energy beam generated by an irradiation device is directed onto a powder bed to melt and/or sinter sequential layers of powder material
Data Source
AI summary
An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device that includes a plurality of laser diode arrays. Respective ones of the plurality of laser diode arrays may include a plurality of diode emitters respectively configured to emit an energy beam. The plurality of laser diode arrays may be longitudinally offset relative to one another, and the plurality of laser diode arrays may be laterally offset relative to one another.