Lateral Molten Material Transfer for Uniform Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing systems, such as Direct Metal Laser Melting, face challenges in achieving uniform material deposition, leading to inefficiencies and increased costs due to non-uniform features and material wastage, particularly in creating containment walls to prevent particulate material from sliding off components.
Innovation Solution
The system employs a consolidation device that creates a surface tension gradient by repetitive laser re-melting to transfer molten material from one region to another, allowing for lateral material transfer and correction of non-uniformities in situ, using a recoating device to spread particles and form layers with varying thicknesses, thereby addressing the need for complex component fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing systems use standard recoating devices to deposit particulate material, then the manufacturing process can be completed, but the material deposition becomes non-uniform leading to material wastage and increased costs
Solution Approach 1:
The system changes the physical state parameter of the material from solid particulate to liquid molten state using laser heating, enabling uniform material redistribution through controlled melting and lateral transfer, which resolves the non-uniform deposition issue while reducing material wastage
Solution Approach 2:
The consolidation device performs repetitive laser re-melting cycles on previously deposited layers, periodically remelting and redistributing material to correct non-uniformities, ensuring uniform material distribution without requiring additional particulate material
2Adaptability or versatility
If conventional systems deposit material layer by layer without lateral transfer, then the process is simple, but complex component fabrication requires additional containment walls that increase device complexity and material consumption
Solution Approach 1:
The system uses the deposited material itself as the containment structure by laterally transferring molten material to build up walls where needed, eliminating the need for separate containment wall components and reducing overall device complexity while enabling complex component fabrication
Solution Approach 2:
The consolidation device performs multiple functions: it consolidates material, creates containment walls, and redistributes material laterally, allowing a single device to handle both simple and complex component fabrication without requiring additional specialized components
3Manufacturing precision
If conventional additive manufacturing systems lack lateral material transfer capability, then the system is simpler, but material distribution control is insufficient leading to non-uniform features
Solution Approach 1:
The system replaces mechanical material handling systems with a thermal field-based approach, using laser-induced melting and surface tension gradients to achieve lateral material transfer, thereby improving material distribution control without adding complex mechanical transfer mechanisms
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 creation of complex components with reduced material and energy consumption, correcting errors in real-time and lowering manufacturing costs by ensuring precise control over material distribution and deposition.
Implementation Method 1
creating a surface tension gradient between the first region and the second region
Implementation Method 2
consolidation device that creates a surface tension gradient by repetitive laser re-melting
Implementation Method 3
transfer molten material from a first region within a build layer to a second region
Data Source
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AI summary
An additive manufacturing system (10) includes a build platform (38), a plurality of particles (45) positioned on the build platform (38) defining a build layer (44), a first and second region (82) within the build layer (44), and at least one consolidation device (14). The first region (80) and the second region (82) each including a portion of the plurality of particles (45). The at least one consolidation device (14) is configured to consolidate the plurality of particles (45) within the build layer (44) into a solid, consolidated portion of said build layer (44). The consolidation device (14) is further configured to consolidate at least one of the plurality of particles (45) within the build layer (44) and the solid, consolidated portion of the build layer (44) into a molten volume of transfer material. The consolidation device (14) is further configured to transfer a portion of the molten volume of transfer material within the first region (80) from the first region (80) to the second region (82).