Laser Smoothing Material Extrusion Additive Manufacturing
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Solution Overview
Problem
Material extrusion additive manufacturing techniques produce components with relatively rough surfaces, limiting their technical use due to surface roughness averaging 20 μm, which is exacerbated by layer orientation and extrusion width, and existing post-processing methods are time-consuming and inefficient for achieving smooth surfaces, especially on non-visible areas.
Innovation Solution
Integrating a process where laser beams are directed synchronously with the application of component material in a viscous state to smooth unevenness at the layer boundaries, allowing for simultaneous material shaping or removal, thereby reducing surface roughness without additional post-processing steps, using a combination of extrusion and laser machining as a single process step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If material extrusion additive manufacturing is used to manufacture components, then production freedom and material selection are improved, but surface roughness deteriorates (Ra averages 20 μm)
Solution Approach 1:
The patent combines material extrusion additive manufacturing with laser beam treatment into a single integrated process. The laser beam is directed onto the lateral boundaries of each layer synchronously with material application, merging the manufacturing and surface smoothing operations into one continuous process step, thereby achieving smooth surfaces without separate post-processing
Solution Approach 2:
The laser beam treats the component material while it is still in viscous state immediately after application, performing the surface smoothing action preliminarily during the manufacturing process itself rather than as a subsequent post-processing step. This preliminary action prevents surface defects from setting before they can be corrected
2Manufacturing precision
If mechanical post-processing (milling, turning, grinding) is applied to reduce surface roughness, then surface quality is improved, but manufacturing time increases significantly
Solution Approach 1:
The patent merges the surface smoothing function with the material extrusion process by integrating a laser beam treatment unit that operates synchronously with the extrusion nozzle. This combination eliminates the need for separate mechanical post-processing steps, thereby maintaining high surface quality while preserving manufacturing efficiency
Solution Approach 2:
The patent replaces mechanical post-processing methods (milling, turning, grinding) with a laser beam-based thermal field method. The laser beam directs energy onto the lateral boundaries of layers to smooth surfaces, substituting contact-based mechanical removal with non-contact thermal field processing, thereby reducing manufacturing time while achieving comparable or superior surface quality
3Manufacturing precision
If vibratory grinding with abrasive grains is used to reduce surface roughness by 80-90%, then surface quality is improved, but difficult-to-access regions are inadequately treated and edge rounding occurs
Solution Approach 1:
The patent replaces the mechanical vibratory grinding system with a laser beam-based thermal field method. The laser beam can be directed precisely onto lateral boundaries of layers regardless of component geometry, eliminating the accessibility limitations of mechanical abrasive methods while avoiding unwanted edge rounding effects
Solution Approach 2:
The laser beam treatment is applied selectively to the lateral boundaries of each layer where surface defects occur, rather than treating the entire component surface uniformly. This localized approach ensures precise treatment of problem areas while preserving the integrity of other surfaces
4Manufacturing precision
If laser polishing is applied as a post-processing step, then surface quality is improved, but additional process time is required and only visible surfaces can be accessed
Solution Approach 1:
The patent integrates laser beam treatment directly into the material extrusion process, combining surface smoothing with the manufacturing operation itself. The laser beam treats lateral boundaries synchronously with material application, eliminating the need for separate post-processing time while achieving smooth surfaces on all areas including non-visible regions
Solution Approach 2:
The laser beam performs surface smoothing preliminarily during the manufacturing process while the material is still in viscous state, rather than as a subsequent post-processing step. This preliminary action eliminates the need for additional process time after manufacturing is complete
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 enables the production of components with low surface roughness on both visible and non-visible areas during manufacturing, reducing the need for post-processing, increasing build-up rates, and maintaining consistent surface quality, thus making material extrusion more economically viable for industrial applications.
Implementation Method 1
at least one laser beam directed onto a lateral boundary of the layer
Implementation Method 2
The energy of the laser is used to melt or vaporise the material selectively
Data Source
AI summary
The invention relates to a process and an assembly for additive manufacturing of components by material extrusion, wherein the components are built up layer by layer from a component material which is applied in viscous state on top of a carrier. In the process, the component material applied in each case as a layer, while still in viscous state, is machined in synchrony with application with at least one laser beam directed onto a lateral boundary of the layer, preferably to achieve smoothing of unevennesses on surfaces of the component. The process allows manufacturing of components by material extrusion with reduced surface roughness even on non-visible surfaces, without any need for post-processing.