Additive Manufacturing Laser Load Balancing for Build Time Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In additive manufacturing, multiple lasers cannot work on the same area simultaneously, leading to idle lasers and prolonged build times due to the need for lasers to take turns, which results in inefficient use of resources and potential degradation of part quality from smoke occlusion.
Innovation Solution
A load balancing module is used to determine a prioritized sequence of laser assignments and processing times for regions on a build plate, optimizing laser-to-region assignments to minimize overall completion time, balance workload, and account for smoke drift to prevent quality degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lasers work in parallel on overlapping areas, then productivity increases, but lasers cannot work on the same area simultaneously causing idle time and prolonged build time
Solution Approach 1:
The build plate is divided into multiple discrete regions that can be independently assigned to different lasers. Each region is processed sequentially by its assigned laser, preventing overlap conflicts. This segmentation allows parallel processing while eliminating idle time by ensuring continuous work for each laser across different regions.
Solution Approach 2:
The system performs preliminary assignment of regions to lasers based on spatial proximity and processing requirements. By pre-determining which laser should process which region, the system eliminates idle time and optimizes build time while maintaining parallel productivity benefits.
2Adaptability or versatility
If lasers take turns working on overlapping areas, then multiple lasers can be utilized, but workload distribution becomes uneven and build time increases
Solution Approach 1:
Different regions of the build plate are assigned to different lasers based on their specific characteristics and spatial locations. Each laser is assigned regions that are optically accessible and spatially appropriate, creating a customized workload distribution that optimizes both laser utilization and build time.
Solution Approach 2:
The system dynamically assigns and reassigns regions to lasers based on real-time processing status. When one laser completes its current region, the system can dynamically assign the next available region to maintain continuous operation, optimizing workload distribution and minimizing idle time.
3Manufacturing precision
If sequential processing is used to avoid smoke occlusion, then part quality is maintained, but build time increases significantly
Solution Approach 1:
The build plate is segmented into multiple regions that can be processed in parallel by different lasers. By assigning non-overlapping regions to different lasers, the system maintains smoke occlusion prevention (each laser works on its assigned region without interference) while enabling simultaneous processing, thus reducing build time significantly compared to sequential processing.
Solution Approach 2:
The system performs preliminary assignment of regions to lasers, determining the optimal processing sequence and assignment before execution. This pre-planning ensures that lasers are assigned regions in a way that minimizes smoke occlusion risks while maximizing parallel processing efficiency, reducing overall build time while maintaining part 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, optimizes labor costs, and ensures high-quality parts by equitably distributing workload among lasers and minimizing smoke interference, achieving near-optimal assignments in a few minutes for hundreds of regions.
Implementation Method 1
The laser solidifies the powdered material by sintering or melting the powdered material
Implementation Method 2
The laser solidifies the powdered material by sintering or melting the powdered material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
According to some embodiments, system (100) and methods are provided comprising receiving input (101) including: coordinates of one or more regions (118) to be fabricated on a build plate (102), a laser boundary (302) for each of two or more lasers (106), wherein the lasers (106) fabricate the one or more regions (118), and a processing time (510) for each region (1); deriving a prioritized sequence (118) of the one or more regions (118) to be fabricated; determining, based on the received coordinates and received laser boundary (302), one or more potential lasers (106) assignments for each region (1); determining, based on the determined potential laser assignments (514), the prioritized sequence (118) of the one or more regions (118), and the processing time (510) for each region (1), a laser-to-region sequence (602) for the one or more lasers (106) to fabricate the one or more regions (118); assigning the determined laser-to-region sequence (602) to the one or more lasers (106) for fabrication of the one or more regions (118). Numerous other aspects are provided.