Laser Sintering Machine with Parallel Kinematics for Large Volume Precision
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Solution Overview
Problem
Current additive manufacturing technologies for large metal or metal alloy objects by laser sintering face limitations in size due to inefficiencies and deformations in powder usage, particularly in powder bed technology, and low precision and productivity in metal deposition methods.
Innovation Solution
A laser operating machine with a transport structure allowing movement along Cartesian axes and redundant parallel kinematics, combined with an optical assembly for dynamic laser beam control, enables precise and rapid sintering by moving nozzles and a laser spot within a conical space, allowing for flexible and high-accuracy powder deposition and sintering across large volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If powder bed technology is used for additive manufacturing, then manufacturing precision is maintained, but the device is limited in size and cannot efficiently handle large-volume objects
Solution Approach 1:
The system segments the manufacturing process into two independent subsystems: a transport structure for positioning the workpiece and a movable element with nozzles for localized powder deposition. This segmentation allows the workpiece to be manufactured in large volumes while maintaining precision through controlled localized deposition only where needed, avoiding the limitations of traditional powder bed technology that requires entire layers to be deposited.
Solution Approach 2:
The system employs dynamic movement capabilities with the movable element that can independently position multiple nozzles in three-dimensional space relative to the workpiece. This dynamic positioning allows precise control of powder deposition locations and enables the system to adapt to complex geometries and large volumes simultaneously, resolving the contradiction between size and precision.
2Volume of moving object
If metal deposition technology is used for large part manufacturing, then manufacturing volume is increased, but manufacturing precision and productivity decrease due to slow movement axes
Solution Approach 1:
The system replaces the traditional single mechanical axis system with a parallel kinematics mechanism that provides redundant movement axes. This substitution enables the movable element to achieve precise positioning through collaborative movement of multiple axes working in parallel, significantly improving both speed and precision compared to sequential mechanical axis movement in conventional metal deposition systems.
Solution Approach 2:
The movable element is designed with multi-functionality, capable of simultaneously performing powder deposition, protection gas delivery, and precise positioning operations. The redundant parallel kinematics axes provide universal movement capability in three-dimensional space, allowing the system to maintain high precision while handling large-volume workpieces, thus resolving the limitations of traditional metal deposition systems.
3Volume of moving object
If traditional metal deposition with aligned nozzle and laser beam is used, then large parts can be manufactured, but productivity is low due to slowness of movement axes
Solution Approach 1:
The system implements dynamic parallel kinematics with redundant axes that enable high-speed movement of the movable element while maintaining precise positioning. The collaborative movement of multiple axes in parallel allows the system to rapidly reposition nozzles and deliver powder to required locations, significantly increasing manufacturing speed compared to traditional sequential axis movement, thus resolving the productivity limitation.
Solution Approach 2:
The system segments the powder delivery and laser processing functions into independent components that can operate semi-independently. The movable element with multiple nozzles can be positioned rapidly using parallel kinematics, while the laser beam follows the deposited powder path. This segmentation allows optimized movement speeds for each function, improving overall productivity while maintaining part quality.
4Volume of moving object
If powder bed technology is used for large chambers, then large objects can be accommodated, but powder usage efficiency decreases and deformations occur
Solution Approach 1:
The system applies local quality by depositing powder only in the specific locations where material is required for the part geometry, rather than depositing entire layers across the entire build area. The movable element with targeted nozzles delivers powder locally to the laser processing zone, significantly reducing powder waste and improving usage efficiency while accommodating large chamber sizes. This localized deposition approach eliminates the powder inefficiency inherent in traditional powder bed technology for large chambers.
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 solution enhances precision and productivity in additive manufacturing by enabling large-volume, high-accuracy sintering with reduced deformation and improved powder usage efficiency, combining the advantages of powder bed and metal deposition technologies.
Implementation Method 1
laser means for conveying a laser beam (L) in a laser spot (S) focused on said work substrate to sinter said powders
Implementation Method 2
additive manufacturing of objects by laser sintering
Implementation Method 3
converging the beams of a plurality of laser beams incident on said movable element with parallel kinematics onto a common focal point
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
Laser operating machine for additive manufacturing of objects by laser sintering, comprising a transport structure (11), which is movable in a work space (100), operating according to a first system of movement axes (X, Y, Z) and configured to support one or more nozzles (34) for emitting sintering powder jets to be sintered on a work substrate (100, 110) and an optical laser assembly (20) for conveying a laser beam (L) in a laser spot (S) focused on said work substrate (100, 110) to sinter said powders, According to the invention, said optical laser assembly (20) is integrally associated with said transport structure (11) and a movable element (12) is also integrally associated with said transport structure (11) operating according to a second system of movement axes (u, v), said movable element (12) comprising a tool-carrier frame (30), on which one or more nozzles (34) for emitting sintering powder jets are arranged, associated with said second system of movement axes (u, v) and movable with respect to said optical laser assembly (20).