3D Printing Laser Scan Path Rotation to Suppress Bulge Formation
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Solution Overview
Problem
In additive manufacturing, the formation of bulges during the lamination of solidified layers due to uneven raster scan lines can lead to non-uniform material layers and manufacturing quality issues, particularly when raster scanning is performed without dividing the irradiation area, resulting in collisions with the material layer forming device and potential cessation of the manufacturing process.
Innovation Solution
A manufacturing method that involves dividing the irradiation area into smaller sections and rotating the division direction by a specific angle (0°<θ<180° or −180°<θ<0°) to set raster scan lines within these sections, ensuring uniform irradiation and reducing the repetition of short raster scan lines, thereby minimizing bulge formation and maintaining manufacturing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If raster scanning is performed for each divided area, then uniform irradiation energy and stable manufacturing quality are improved, but short raster scan lines occur at the end of the irradiation area causing bulge formation
Solution Approach 1:
The irradiation area is divided into multiple divided areas along a division direction, and the division direction is rotated by a predetermined angle for each successive irradiation area. This segmentation approach ensures that short raster scan lines do not repeatedly occur at the same position, distributing the bulge formation risk and maintaining manufacturing precision.
Solution Approach 2:
The division direction is rotated by a predetermined angle (e.g., 45 degrees) for each successive irradiation area, creating an asymmetric pattern in the raster scan line distribution. This asymmetry prevents the repetition of short scan lines at the same position, thereby suppressing bulge formation while maintaining uniform irradiation energy distribution.
2Shape
If raster scanning is performed without dividing the irradiation area, then long reference length of raster scan line reduces bulge formation, but adverse thermal effects and spatters increase
Solution Approach 1:
The irradiation area is divided into multiple smaller divided areas, each with its own raster scan lines of appropriate reference length. This segmentation allows the laser beam to scan at high speed over short distances, reducing thermal effects and spatters, while the rotation of division directions prevents bulge formation that would occur with repeated short scan lines.
Solution Approach 2:
The division direction is dynamically rotated for each successive irradiation area, adapting the raster scan pattern to prevent short scan lines from occurring at the same position. This dynamic adjustment maintains the benefits of short scan lines (reduced thermal effects) while eliminating the disadvantage of repeated bulge formation.
3Productivity
If high speed scanning is performed, then productivity is improved, but heat effects on surroundings and required pause time increase
Solution Approach 1:
The irradiation area is divided into multiple small divided areas, enabling the laser beam to scan each area quickly. The short reference length of raster scan lines in each divided area allows high-speed scanning, improving productivity while minimizing heat accumulation and thermal effects on surrounding material.
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 effectively suppresses the formation of bulges and maintains high-quality manufacturing by ensuring uniform irradiation and consistent material layer formation, allowing for continuous production without interruptions.
Implementation Method 1
By irradiating a predetermined position in the material layer with a laser beam or an electron beam, the material layer is sintered or melted
Implementation Method 2
the material layer is sintered or melted, and a solidified layer is formed
Implementation Method 3
the material layer is sintered or melted, and a solidified layer is formed
Data Source
AI summary
A manufacturing method of a three-dimensional object includes: a solidified layer forming step of repeating a material layer forming step and a solidification step and laminating a solidified layer; a manufacturing condition setting step of setting an irradiation condition and a division width; an irradiation area determining step of determining an irradiation area for each divided layer obtained by dividing a three-dimensional shape; a dividing step of dividing the irradiation area by the division width along a division direction and forming a divided area; and a scan line setting step of setting a raster scan line within the divided area. A laser beam is scanned along a scan path including the raster scan line. A direction obtained by horizontally rotating the division direction of the irradiation area in a target divided layer is taken as the division direction in the divided layer directly above the target divided layer.