Laser Pixel Group Switching for Reliable Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing systems using multiple laser energy sources face increased likelihood of laser pixel failures during multi-day print processes, leading to incomplete or flawed parts due to the inability to effectively manage and switch between viable and failed laser pixels.
Innovation Solution
An additive manufacturing system identifies and selects groups of contiguous viable laser pixels, allowing for the formation of parts using a subset of the total laser pixels, and switches to alternative groups if failures occur, utilizing a processor to monitor and manage laser pixel performance and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser energy sources are used to increase productivity, then the manufacturing speed and throughput are improved, but the likelihood of laser pixel failures increases during multi-day print processes
Solution Approach 1:
The system divides the laser pixel array into multiple independent groups, where each group can be independently activated and monitored. When a failure occurs in one group, the system can switch to another group without affecting the entire manufacturing process. This segmentation isolates failures to specific segments rather than causing system-wide disruptions.
Solution Approach 2:
The system dynamically changes operational parameters by switching between different groups of laser pixels based on their viability status. The controller monitors performance parameters of each laser pixel and adjusts the active group configuration in real-time, transitioning from a static all-or-nothing approach to a dynamic selective activation approach that maintains reliability while preserving productivity.
2Loss of time
If all laser pixels are used to form parts, then the build time is reduced, but any single failure can compromise the entire part quality and completeness
Solution Approach 1:
The system prepares multiple groups of laser pixels in advance, with each group capable of independently forming complete parts. This redundancy acts as a cushion against failures, ensuring that if one group fails, another pre-prepared group can immediately take over without interrupting the build process or compromising part quality.
Solution Approach 2:
The system creates redundant copies of functional laser pixel groups that can serve as backups. Each group is configured to perform the same manufacturing function, allowing the system to switch between identical functional copies when failures occur, thereby maintaining consistent part quality throughout the build process.
3Device complexity
If laser pixel failures are not monitored and managed, then the system complexity is reduced, but part losses and defects increase significantly
Solution Approach 1:
The system implements continuous feedback monitoring of laser pixel performance through the controller, which detects failures in real-time and automatically triggers group switching operations. This feedback loop enables the system to respond to failures immediately, preventing defective parts from being produced and minimizing material loss without requiring complex manual intervention.
Solution Approach 2:
The system performs self-diagnosis and self-correction by automatically detecting laser pixel failures and switching to backup groups without external intervention. The controller monitors the health of each laser pixel and autonomously reconfigures the active groups to maintain manufacturing continuity, reducing the need for complex external monitoring systems.
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 enhances the reliability of additive manufacturing processes by reducing part losses and defects, shortening build times, and increasing throughput by better managing laser pixel redundancy and rapid switchover between pixel groups.
Implementation Method 1
a plurality of laser energy sources and an optics assembly configured to direct laser energy from the one or more laser energy sources toward the build surface to form a corresponding plurality of laser pixels on the build surface
Implementation Method 2
a portion of the layer may be fused through exposure to one or more energy sources, such as laser energy sources, to create a desired two-dimensional geometry of solidified material within the layer
Data Source
AI summary
Additive manufacturing systems and methods related to the selection and use of groups of laser pixels from an array of laser pixels including a plurality of laser pixels are disclosed. According to some embodiments a plurality of laser pixels may be divided into one or more groups of laser pixels based on one or more process parameters and/or based on the identification of failed laser pixels. The groups may be include fewer laser pixels than the overall array of laser pixels. In some embodiments, an additive manufacturing system may switch between laser pixel groups during a manufacturing process to provide redundancy and/or to enable continued operation of the system even when laser pixel failures occur.