Laser Hot Wire Deposition Head for Omni-Directional Build Paths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing processes require frequent adjustments in the orientation of deposition equipment and complex optical implementations, leading to increased complexity, cost, and difficulty in producing parts with moderately complex geometry, especially when rotational orientation is directionally dependent on the path.
Innovation Solution
A laser hot wire deposition head with a longitudinally oriented laser beam and a filler wire fed at an angle of 30 degrees or less, integrated into a single deposition head, allowing omni-directional build paths without the need to change the orientation of the deposition head or split/recombine the laser beam, thus simplifying path planning and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing processes use traditional deposition equipment orientation adjustment, then parts can be manufactured, but the equipment orientation must be constantly adjusted and path planning becomes complex
Solution Approach 1:
The deposition head is designed with a universal configuration that can deposit material in any direction without requiring orientation changes. The longitudinal laser beam and angled wire feed (≤30 degrees) combination creates a universal deposition capability that works for omni-directional build paths, eliminating the need for complex rotational adjustments while maintaining manufacturing versatility
Solution Approach 2:
Instead of rotating the deposition head to change build path direction (conventional approach), the invention inverts the approach by keeping the deposition head orientation fixed and using the angled wire feed relative to the longitudinal laser beam to achieve directional versatility. This inversion simplifies the system by eliminating complex rotational mechanisms
2Ease of manufacture
If complex optical implementations are used to split and recombine laser beams, then deposition can be achieved, but the optical system becomes costly and complex
Solution Approach 1:
The invention extracts the wire feed system from the optical path, allowing the laser beam to travel in a simple longitudinal path without being split or recombined. The wire is fed at an angle (≤30 degrees) to the laser beam axis, separating the optical function from the material delivery function, thereby eliminating complex optical components while maintaining effective deposition
Solution Approach 2:
The deposition head merges the longitudinal laser beam path with the angled wire feed into a single integrated tool. This combination allows both the laser energy and wire material to converge at the deposition point without requiring complex optical splitting and recombining mechanisms, simplifying the overall system while achieving effective material placement
3Manufacturing precision
If rotational orientation of deposition equipment is adjusted for different paths, then deposition accuracy can be maintained, but umbilical winding and unwinding becomes complex and time-intensive
Solution Approach 1:
The deposition head is preliminarily configured with a fixed longitudinal laser beam orientation and an angled wire feed (≤30 degrees) that is optimized for omni-directional deposition. This preliminary configuration eliminates the need for time-consuming reorientation adjustments during different path segments, as the fixed geometry inherently supports deposition in any direction without requiring equipment rotation or umbilical remanagement
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
Enables efficient, cost-effective, and time-saving additive manufacturing by allowing omni-directional movement of the deposition head without altering its orientation, enhancing versatility and reducing production costs for parts with complex geometries.
Implementation Method 1
a laser focusing device that is mounted within the frame and is configured to emit a single beam path laser beam in a longitudinally-oriented direction toward a surface of a substrate or a part to be additively manufactured
Implementation Method 2
The wire feeding device and contact tube are mounted within the frame and are configured to feed a consumable filler wire toward the substrate or part at an angle of between 1° and 30° with respect to the longitudinally-oriented direction
Implementation Method 3
The deposition head is configured to be moved omni-directionally with respect to the substrate or the part, under the guidance of a motion control system, to additively manufacture the part
Data Source
AI summary
Embodiments of an integrated laser hot wire deposition head are disclosed. In one embodiment, the deposition head includes a structural frame, a laser process sub-system, a wire feeding device, and a contact tube. The laser process sub-system is mounted within the structural frame to deliver a single beam path laser beam in a longitudinally-oriented direction toward a substrate or a part to be additively manufactured. The wire feeding device and contact tube are mounted within the frame to feed a consumable filler wire toward the substrate or part at an angle with respect to the longitudinally-oriented direction. The deposition head can be moved omni-directionally with respect to the substrate or the part, under the guidance of a motion control system, to additively manufacture the part without having to angularly change an orientation of the single beam path laser beam from the longitudinally-oriented direction or rotate the deposition head.