Additive Manufacturing Laser Sintering Deformation Control
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Solution Overview
Problem
In additive manufacturing of metal three-dimensional objects via laser sintering, unpredictable changes in sintering conditions can lead to deformations and abnormal sintered parts, causing the blade to be caught and potentially damaged, even when shaping is performed under appropriate laser irradiation conditions.
Innovation Solution
A method that involves acquiring three-dimensional shaping data to detect deformed parts, generating corrected layer shaping data to exclude the deformed region from the laser irradiation area, and forming subsequent powder layers to sinter only the regions where deformations are not present, thereby preventing continuous deformation and blade damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser sintering is performed under appropriate conditions, then normal sintered layers are formed, but unpredictable changes in sintering conditions can still cause deformations and abnormal sintered parts
Solution Approach 1:
The patent implements a feedback mechanism by detecting the upper surface shape of each sintered layer and using this information to adjust the laser irradiation conditions for subsequent layers. The detection unit measures the actual surface topology, and the control unit modifies laser parameters based on detected deformations, creating a closed-loop control system that compensates for unpredictable sintering variations.
Solution Approach 2:
The patent dynamically changes laser irradiation parameters (such as power, speed, or scanning pattern) based on the detected surface shape of previously sintered layers. When deformations are detected, the control unit adjusts the laser parameters to prevent the formation of similar deformations in subsequent layers, adapting the sintering process in real-time.
2Productivity
If deformed parts are not addressed, then the additive manufacturing process continues, but the blade may be caught and damaged
Solution Approach 1:
The patent performs preliminary detection of the upper surface shape of each sintered layer immediately after formation and before the next powder layer is applied. By detecting deformations early and adjusting subsequent laser irradiation accordingly, the system prevents deformed parts from growing tall enough to interfere with the blade, thereby protecting the blade while maintaining continuous production.
Solution Approach 2:
The patent introduces an intermediary detection and control system between the sintering process and the blade operation. The detection unit acts as an intermediary that monitors surface topology, and the control unit serves as an intermediary that adjusts laser parameters based on detected conditions, preventing direct interaction between deformed parts and the blade.
3Productivity
If the blade flattens powder layers over deformed parts, then layer formation continues, but the deformed part reaches predetermined height and catches the blade
Solution Approach 1:
The patent performs preliminary detection of surface deformations before subsequent powder layers are applied. By detecting the upper surface shape early and adjusting laser irradiation parameters for the next layer based on this detection, the system prevents deformed parts from reaching heights that would interfere with blade operation, ensuring smooth continuous operation.
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 prevents the blade from being caught by deformed parts, maintaining the integrity of the additive manufacturing process and ensuring consistent layer formation by avoiding areas with deformations during the sintering process.
Implementation Method 1
a laser irradiation device is used to irradiate a predetermined range of the powder layer with laser to form a sintered layer
Implementation Method 2
The disclosure relates to a method of additive manufacturing a three-dimensional object of metal by laser sintering
Data Source
AI summary
The disclosure provides a method of additive manufacturing a three-dimensional object, which can prevent a blade from being caught by a deformed part that is generated due to an unpredictable change of a sintering condition. In the method of additive manufacturing the three-dimensional object, if a deformed part having any height is generated on the upper surface of the nth sintered layer, when the next n+1th sintered layer is formed, the n+1th powder layer is irradiated with laser by avoiding the region where the deformed part is generated. Then, after the n+2th powder layer is formed, the unsintered part is sintered together with the n+2th powder layer.