Laser Array Scan Angle Control for Uniform Melt Pool Spacing
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in controlling laser beam paths, particularly with non-axisymmetric spots, leading to uneven energy distribution, unpredictable distortion, and anisotropic distortion in printed parts.
Innovation Solution
Implementing angled scanning by controlling the scan angle of laser assemblies relative to the build surface, adjusting laser energy profiles, and selectively activating laser energy sources to achieve consistent energy distribution and controlled melt pool spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser scanning is used with non-axisymmetric spots, then manufacturing process is simple, but energy distribution is uneven and distortion is unpredictable
Solution Approach 1:
The patent implements dynamic scan angle control where the laser assembly can rotate to different angles relative to the build surface. This dynamic adjustment allows the system to compensate for non-axisymmetric spot characteristics and achieve uniform energy distribution by varying the scanning trajectory angle, thereby resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The patent changes the scanning parameter (scan angle) to optimize energy distribution. By adjusting the angle at which the laser scans across the build surface, the system can deliver more uniform energy distribution even with non-axisymmetric spots, transforming a fixed-parameter process into a variable-parameter process that adapts to spot characteristics.
2Productivity
If laser scanning speed is increased to improve productivity, then manufacturing speed increases, but energy density decreases leading to poor fusion
Solution Approach 1:
The patent employs multiple parameter adjustments including scan angle, laser power, and scan speed to maintain optimal energy density. By changing the scan angle and adjusting laser power dynamically, the system can compensate for reduced dwell time at higher speeds, thereby maintaining both productivity and fusion quality without being constrained by the traditional speed-density tradeoff.
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 reduces peak distortion, minimizes destructive interference, and produces more isotropic parts by ensuring uniform energy delivery and controlled melt pool formation.
Implementation Method 1
one or more laser beams are scanned over a thin layer of metal powder... laser power, laser spot size, and/or laser scanning speed are in a regime in which the delivered energy is sufficient to melt the particles of metal powder
Implementation Method 2
The laser beams are scanned along predefined trajectories such that solidified melt pool tracks create shapes corresponding to a two-dimensional slice of a three-dimensional printed part
Data Source
AI summary
Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling the one or more laser energy sources of an additive manufacturing system may be based at least in part on a scan angle and/or desired energy density. Systems and methods for controlling melt pool spacing are also described.