Laser Array Scan Paths for Precise and Efficient DMLM
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Solution Overview
Problem
Existing additive manufacturing systems, such as DMLM, suffer from inefficient utilization of laser arrays due to most lasers being OFF for the majority of the time during component buildup, leading to increased manufacturing costs.
Innovation Solution
Implement novel scan strategies that include rotating or stationary build platforms in combination with laser arrays, allowing only a portion of the lasers to be ON at any given time, and using rotating or stationary recoaters to optimize laser beam usage based on component geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all lasers are turned ON 100% of the time, then manufacturing time is reduced and cost is decreased, but manufacturing precision deteriorates because lasers must be turned OFF in areas that do not make up the component
Solution Approach 1:
The laser array is divided into multiple independently controllable laser beams, allowing selective activation of only those lasers corresponding to the component geometry at any given moment during the scanning process
Solution Approach 2:
The system dynamically adjusts which lasers are active based on real-time scan position and component geometry requirements, optimizing the balance between productivity and precision
2Manufacturing precision
If lasers are selectively turned ON and OFF during scanning, then manufacturing precision is maintained, but laser utilization efficiency deteriorates causing increased manufacturing cost
Solution Approach 1:
The scanning strategy is designed to minimize idle time between active laser operations, maintaining continuous useful action by optimizing the sequence and timing of laser activation across the array
Solution Approach 2:
The system pre-calculates and plans the laser activation sequence based on the component geometry and scan path, preparing which lasers should be active before reaching each position to minimize transition time
3Manufacturing precision
If a large number of lasers are used in the array, then manufacturing precision and component quality improve, but device complexity and manufacturing cost increase
Solution Approach 1:
The laser array system is designed to be universally applicable to various component geometries and sizes, with the same hardware configuration able to adapt to different manufacturing requirements through software-controlled scan strategies
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
Enhances laser array utilization, reducing manufacturing costs and time by ensuring efficient laser operation, thereby improving the overall efficiency and cost-effectiveness of the additive manufacturing process.
Implementation Method 1
The laser arrays generate multiple laser beams that melt the powder material on the build platform in and around the area where the laser beams are incident on the powder material, resulting in a melt pool
Data Source
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AI summary
An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.