3D Printing Laser Control for Solidified Layer Quality

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Solution Overview

Problem

Existing lamination molding methods struggle to consistently produce high-quality three-dimensional molded objects due to inappropriate settings of laser power, beam diameter, and scanning speed, which can lead to suboptimal or unstable solidified layers.

Innovation Solution

A method and apparatus that calculate and verify the laser power, scanning speed, and beam diameter during the formation of solidified layers, determining if they fall within predetermined reference ranges to ensure the quality of the molded object.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser power, beam diameter, and scanning speed are set to desired values, then the efficiency of solidified layer formation is improved, but the quality and stability of the molded object deteriorate due to inappropriate settings or apparatus failures

Engineering Contradiction:

Improveefficiency of solidified layer formationVSAvoidquality of molded object

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements real-time monitoring of laser power, beam diameter, and scanning speed during the solidified layer formation process. A control unit continuously acquires actual values of these parameters and compares them against predetermined reference ranges to detect deviations that would compromise molded object quality.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent establishes predetermined reference ranges for laser power, beam diameter, and scanning speed before the molding process begins. These reference values serve as pre-established criteria against which actual process parameters are compared, enabling proactive quality control before defects occur.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If real-time monitoring of laser power, beam diameter, and scanning speed is implemented, then the quality of the molded object is improved, but the complexity of the apparatus increases

Engineering Contradiction:

Improvequality of molded objectVSAvoidcomplexity of lamination molding apparatus

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The control unit performs multiple functions: it manages the laser beam generation, focuses the beam to desired diameter, controls scanning speed, and simultaneously monitors all these parameters against reference ranges. This multi-functionality reduces the need for separate monitoring systems and minimizes overall apparatus complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the control functions for laser power regulation, beam diameter control, and scanning speed management into a single integrated control unit. This consolidation merges multiple control mechanisms into one system, simplifying the overall apparatus structure while maintaining comprehensive quality monitoring.

Inventive Principle:

Principle #5Merging (Combining)

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 allows for the production of highly accurate three-dimensional molded objects by determining the appropriateness of the laser power, scanning speed, and beam diameter, ensuring the stability and quality of the solidified layers.

Implementation Method 1

irradiation of the material layer with a laser beam

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

formation of a solidified layer by irradiation of the material layer with a laser beam

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11541604B2Method for producing three-dimensional object using movable lens with control of laser power, scan speed and beam diameter

Publication Date: 2023.01.03 SODICK CO LTD

AI summary

A method for producing a three-dimensional molded object includes forming a solidified layer, calculating a laser power, calculating a scanning speed, calculating a beam diameter, and determining that the solidified layer is poor when the laser power is outside a first reference range related to the laser power, the scanning speed is outside a second reference range related to the scanning speed, or the beam diameter is outside a third reference range related to the beam diameter.