Additive Manufacturing Laser Controller for Dynamic Melt Pool Control
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Solution Overview
Problem
Additive manufacturing systems, such as Direct Metal Laser Melting (DMLM), face challenges with long build times and inconsistent cooling rates, which hinder the realization of cost benefits and result in components with temperature issues.
Innovation Solution
A controller system that generates non-uniform energy intensity profiles along scan paths based on a functional relationship between generating and scan path points, allowing for independent control of laser power output to optimize melt pool formation and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional uniform scanning is used, then the process is simple to implement, but build time is excessively long (70-100 seconds per layer)
Solution Approach 1:
The patent applies dynamics by transitioning from static uniform scanning to dynamic adaptive scanning. The scan path generation is made dynamic through functional relationships that adapt to local geometry characteristics, allowing the system to optimize scanning speed and energy distribution in real-time based on the component being fabricated, thereby reducing build time without excessive complexity
Solution Approach 2:
The patent changes key parameters of the scanning process by introducing non-uniform energy intensity profiles and variable scan speeds based on functional relationships. Instead of fixed uniform parameters, the system dynamically adjusts energy distribution and scanning characteristics to match local geometric requirements, achieving faster build times while maintaining manufacturing quality
2Productivity
If rapid cooling is used to reduce build time, then productivity increases, but temperature consistency deteriorates (temperature falls below minimum requirements)
Solution Approach 1:
The patent applies local quality by implementing spatially varying energy intensity profiles that adapt to local thermal conditions and geometry. Different regions of the build chamber receive customized energy distribution - areas requiring higher temperatures maintain it longer, while other regions can cool faster - thereby achieving both reduced build time and maintained temperature consistency through localized control
Solution Approach 2:
The patent implements feedback mechanisms where the scan path generation and energy intensity profiles are based on functional relationships that respond to local geometric and thermal conditions. This feedback loop allows the system to adjust energy distribution and cooling rates dynamically, ensuring temperature requirements are met while optimizing build time
3Ease of manufacture
If uniform energy intensity is applied, then the laser control is simple, but melt pool characteristics are inconsistent
Solution Approach 1:
The patent applies local quality by implementing spatially varying energy intensity profiles that adapt to local thermal conditions and geometry. Different regions of the build chamber receive customized energy distribution - areas requiring higher temperatures maintain it longer, while other regions can cool faster - thereby achieving both reduced build time and maintained temperature consistency through localized control
Solution Approach 2:
The patent changes key parameters of the scanning process by introducing non-uniform energy intensity profiles and variable scan speeds based on functional relationships. Instead of fixed uniform parameters, the system dynamically adjusts energy distribution and scanning characteristics to match local geometric requirements, achieving faster build times while maintaining manufacturing quality
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 build time, enhances manufacturing efficiency, and ensures consistent melting characteristics, addressing the limitations of existing systems by dynamically adjusting energy output to match thermal loss rates and geometry complexities.
Implementation Method 1
The at least one laser device is configured to generate at least one melt pool in a layer of powdered material
Implementation Method 2
The controller is configured to generate a non-uniform energy intensity profile for the at least one scan path of the at least one laser device
Data Source
AI summary
A controller for use in an additive manufacturing system including at least one laser device configured to generate at least one melt pool in powdered material including a processing device and a memory device. The controller is configured to generate at least one control signal to control a power output of the at least one laser device throughout at least one scan path across the layer of powdered material, the scan path generated at least partially based on a functional relationship between a plurality of points of a generating path and each point of a plurality of points of the scan path. The controller is further configured to generate a non-uniform energy intensity profile for the scan path, and transmit the control signal to the laser device to emit at least one laser beam to generate at least one melt pool.