Laser Exposure Path Control for Homogeneous Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in achieving homogeneous object properties due to impurities like metal vapors and spatter, which complicate the manufacturing process and result in inhomogeneous mechanical properties, especially in large build areas.
Innovation Solution
The method controls the energy input device by defining the movement vectors of beam bundles relative to a projection center, ensuring angles between these vectors and connection vectors to the projection center are within predetermined limits, and optimizing the scanning order to minimize material displacement and impurity deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the movement direction of the beam bundle is matched to the direction of the gas flow, then the homogeneity of object properties is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent changes the parameter of beam bundle movement direction relative to the gas flow direction. Specifically, it defines that the beam bundle should move against the gas flow direction (180 degrees) rather than matching it, which simplifies the control logic while maintaining improved homogeneity of manufactured objects
Solution Approach 2:
The patent inverts the conventional approach by having the beam bundle move against the gas flow direction rather than with it. This counterintuitive approach simplifies the manufacturing process coordination while still achieving homogeneous object properties
2Manufacturing precision
If the beam bundle movement is coordinated with gas flow direction, then object properties improve, but inhomogeneities persist in extensive build areas
Solution Approach 1:
The patent introduces a new parameter relationship where the beam bundle movement direction is set at 180 degrees to the gas flow direction. This parameter change ensures consistent material deposition characteristics across the entire build area, eliminating the inhomogeneities that persisted in previous approaches for extensive build areas
3Manufacturing precision
If gas flow is used to minimize impurity influence, then object properties improve, but the manufacturing process becomes more complex
Solution Approach 1:
The patent simplifies the manufacturing process by defining a fixed 180-degree relationship between beam bundle movement and gas flow direction. This clear parameter specification reduces process complexity while maintaining the ability to minimize impurity influence and achieve homogeneous object properties
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 results in additively manufactured objects with improved homogeneity and reproducibility of properties, reducing the impact of impurities and enhancing the mechanical properties of the manufactured components.
Implementation Method 1
energy in the form of electromagnetic radiation or particle radiation is selectively supplied to a layer of a shapeless building material. The radiation supplied to the building material heats up the building material and thus causes a sintering or melting process
Implementation Method 2
in laser sintering or laser melting, a laser beam is moved across those points of a layer of the building material that correspond to the object cross-section of the object to be produced in this layer, so that the building material is solidified at these points
Data Source
AI summary
Disclosed is a method for controlling an energy input device of an additive manufacturing device. A beam bundle deflection center is assigned to each of the number of beam bundles from which this beam bundle is directed onto the build plane. Each beam bundle deflection center is assigned a projection center corresponding to a perpendicular projection of the position of the beam bundle deflection center onto the build plane. The directions of the movement vectors of the number of beam bundles when scanning the trajectories are defined such that at each of the solidification points in this section the movement vector has an angle with respect to a connection vector from this solidification point to the projection center of the beam bundle used, which angle is smaller than a predetermined maximum angle γ1.