Laser Beam Shaping With Surface Position Feedback for Metal 3D Printing
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Solution Overview
Problem
Metallic 3D printing technologies, such as PBF and DED, face issues with fabrication accuracy, surface finish roughness, slow processing speed, and cumbersome powder handling, limiting their economic rationality and convenience in manufacturing.
Innovation Solution
A shaping apparatus and method that includes a movement system, measurement system, and beam shaping system controlled by a controller to accurately position and irradiate a beam on a target surface, allowing for precise application of shaping material based on 3D data, enhancing processing accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If PBF (Powder Bed Fusion) is used for metallic 3D printing, then three-dimensional shaped objects can be formed, but processing speed is slow
Solution Approach 1:
The patent implements continuous energy deposition and material placement without the intermittent powder spreading steps required in PBF. The laser beam and material feed operate continuously, maintaining useful action throughout the process, which significantly increases processing speed while preserving fabrication accuracy through precise control of the deposition parameters.
2Ease of operation
If DED (Directed Energy Deposition) is used for metallic 3D printing, then powder handling is improved compared to PBF, but processing accuracy and surface finish still need improvement
Solution Approach 1:
The patent adjusts the deposition parameters including material feed rate, laser power, and scanning speed to optimize the molten pool dynamics. By controlling these parameters, the system achieves precise material placement and smooth surface finish, improving processing accuracy while maintaining the ease of powder handling inherent in DED.
Solution Approach 2:
The patent incorporates feedback control mechanisms that monitor the deposition process in real-time and adjust parameters accordingly. This feedback system ensures consistent material placement accuracy and surface quality by compensating for variations in material flow, laser power, or thermal conditions during the deposition process.
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
The solution enables the formation of three-dimensional shaped objects with improved processing accuracy and efficiency, addressing the limitations of existing metallic 3D printing technologies by optimizing movement and material application.
Implementation Method 1
a high power laser beam is scanned thereon using a galvano mirror or the like, and the part where the beam hits is melted and solidified
Implementation Method 2
PBF printers, a thin layer of powdered sintered metal is formed on a bed where an object to be worked is mounted, a high power laser beam is scanned thereon
Implementation Method 3
a method of depositing melted metal material on a processing subject is employed. For example, powdered metal is jetted around the focus of a laser beam condensed by a condensing lens
Implementation Method 4
The powdered metal melts into a liquid form by irradiation of a laser. When the processing subject is located around the focus, the liquefied metal is deposited on the processing subject, cooled, and then is solidified again
Data Source
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AI summary
This shaping apparatus is equipped with: a movement system which moves a target surface (TAS); a measurement system for acquiring position information of the target surface (TAS) in a state movable by the movement system, a beam shaping system (500) that has a beam irradiation section (520) and a material processing section (530) which supplies a shaping material irradiated by a beam (LB) from beam irradiation section (520); and a controller. On the basis of 3D data of a three-dimensional shaped object to be formed on a target surface and position information of the target surface (TAS) acquired using the measurement system, the controller controls the movement system and the beam shaping system (500) such that a target portion (TA) on the target surface (TAS) is shaped by supplying the shaping material while moving the target surface (TAS) and the beam (LB) from beam irradiation section (520) relative to each other.