Laser Additive-Subtractive Chamber for Precision SLM Finishing
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Solution Overview
Problem
Selective Laser Melting (SLM) technologies face challenges with low precision, poor surface quality, strong residual tensile stress, and internal defects in manufactured parts due to factors like powder size, adhered powder, and uneven heating, limiting the complexity and fineness of structures that can be achieved.
Innovation Solution
A composite device for high-precision laser additive/subtractive manufacturing, featuring a sealed shaping chamber, inert protective gas, independent laser light paths for additive and subtractive processes, and a control unit that enables precise control over machining, allowing for simultaneous ultra-fast laser processing to eliminate step effects and improve surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional SLM technology is used to manufacture parts with complex structures, then near net shaping capability is achieved, but manufacturing precision and surface quality deteriorate due to step effects, adhered powder, and uneven heating
Solution Approach 1:
The patent combines selective laser melting (additive) and ultra-fast laser subtractive manufacturing into a single integrated device. The additive module builds parts layer by layer while the subtractive module simultaneously or sequentially removes material to eliminate step effects and adhered powder, achieving high precision complex structures in one process
Solution Approach 2:
The subtractive manufacturing module performs preliminary removal of excess material and step effects during or immediately after the additive process. This preliminary action prevents defect accumulation and maintains geometric precision throughout the manufacturing process
2Ease of manufacture
If traditional SLM technology is used to manufacture parts with complex structures, then near net shaping capability is achieved, but surface quality deteriorates due to step effects and adhered powder
Solution Approach 1:
The integrated device merges additive and subtractive laser processes, where the subtractive module continuously removes step effects and adhered powder from the surface during or after additive manufacturing, maintaining high surface quality throughout the process
Solution Approach 2:
The subtractive manufacturing process operates continuously or in real-time alongside the additive process, continuously eliminating surface defects rather than waiting for complete part fabrication, thereby maintaining consistent surface quality
3Ease of manufacture
If traditional SLM technology is used to manufacture parts with complex structures, then near net shaping capability is achieved, but residual tensile stress increases due to uneven heating
Solution Approach 1:
The ultra-fast laser subtractive process converts the harmful effect of uneven heating and residual stress by rapidly removing material and redistributing thermal loads. The subtractive process counteracts thermal stress accumulation by creating more uniform heating patterns during material removal
4Ease of manufacture
If traditional SLM technology is used to manufacture parts with complex structures, then near net shaping capability is achieved, but internal defects increase due to powder size and adhered powder
Solution Approach 1:
The subtractive manufacturing module performs preliminary removal of adhered powder and defective material during the additive process, preventing internal defect accumulation before they can compromise part reliability
Solution Approach 2:
The integrated device combines additive and subtractive processes to simultaneously build parts and remove potential defects, creating a self-correcting manufacturing system that reduces internal defect density
5Adaptability or versatility
If separate additive and subtractive manufacturing processes are used, then functional flexibility is maintained, but device complexity and processing time increase
Solution Approach 1:
The patent integrates both additive and subtractive laser manufacturing systems into a single device with shared components (laser source, scanning system, positioning platform). This merging maintains functional flexibility while reducing overall system complexity and enabling simultaneous or coordinated operation of both processes
6Adaptability or versatility
If separate additive and subtractive manufacturing processes are used, then process versatility is maintained, but productivity decreases due to sequential processing
Solution Approach 1:
The integrated device enables simultaneous or coordinated operation of additive and subtractive processes on the same part. The shared positioning system and control unit allow both processes to work in parallel or sequence without requiring separate setup, dramatically improving manufacturing efficiency
Solution Approach 2:
The subtractive process performs preliminary material removal and surface finishing during or immediately after additive manufacturing, eliminating the need for separate post-processing steps and reducing total manufacturing time
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
The device achieves high-precision, high-efficiency, and high-performance additive manufacturing by integrating selective laser melting with ultra-fast laser subtractive technology, enhancing precision, surface quality, and reducing residual stress, enabling complex structures like enclosed cavities and capillary tubes with reduced post-processing costs.
Implementation Method 1
uses high-power laser as heat source to melt metal powder layer by layer
Implementation Method 2
Selective Laser Melting (SLM) is a laser additive manufacturing technology based on manufacturing physical parts by material discrete-gradual accumulation method
Implementation Method 3
utilizes laser additive/subtractive manufacturing technology to complete composite manufacturing... synchronously adopting ultra-fast laser subtractive manufacturing technology
Data Source
AI summary
The present invention discloses a composite device for high-precision laser additive/subtractive manufacturing, which consists of a sealed shaping chamber, an inert protective gas source and a machine-shaping platform; wherein, the inert protective gas source is connected to the sealed shaping chamber; and the machine-shaping platform is arranged in the sealed shaping chamber, as well as there is a light path selection system is arranged right above the machine-shaping platform; in addition, there is a machining position is equipped on the machine-shaping platform, meanwhile, there are lead screws are arranged under the machine-shaping platform.