Lattice Beam Thickness Control for Additive Manufacturing Thermal Uniformity

Solution Overview

Problem

In additive manufacturing, particularly in 3D printing techniques like Multi Jet Fusion, the close proximity of beams and walls in lattice structures can lead to non-uniform thermal effects, resulting in uneven fusion and mechanical properties, as inner areas tend to be fused more than outer areas.

Innovation Solution

A method is developed to control the thickness of lattice structures by determining thermal and re-radiation maps, using machine learning models and simulations to adjust beam thickness based on density and thermal thresholds, ensuring uniform material properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If beam thickness is reduced to achieve finer lattice structures, then manufacturing precision is improved, but thermal uniformity deteriorates due to non-uniform thermal effects in close proximity areas

Engineering Contradiction:

Improvelattice structure precisionVSAvoidthermal uniformity

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by adjusting beam thickness differently across various regions of the lattice structure. Inner beams have different thicknesses compared to outer beams, with specific thickness ranges defined for different spatial locations. This allows each region to have optimized thickness that accounts for local thermal effects, ensuring uniform fusion while maintaining manufacturing precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the beam thickness parameter based on the spatial location and thermal characteristics of different regions. By varying the thickness parameter across the lattice structure according to predefined thresholds and maps, the system achieves uniform material properties while maintaining fine lattice precision.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If beam thickness is increased to improve thermal uniformity, then manufacturing precision deteriorates due to loss of fine lattice detail

Engineering Contradiction:

Improvethermal uniformityVSAvoidlattice structure precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent applies local quality by adjusting beam thickness differently across various regions of the lattice structure. Inner beams have different thicknesses compared to outer beams, with specific thickness ranges defined for different spatial locations. This allows each region to have optimized thickness that accounts for local thermal effects, ensuring uniform fusion while maintaining manufacturing precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the beam thickness parameter based on the spatial location and thermal characteristics of different regions. By varying the thickness parameter across the lattice structure according to predefined thresholds and maps, the system achieves uniform material properties while maintaining fine lattice precision.

Inventive Principle:

Principle #35Parameter changes

3Strength

If lattice structure density is increased to improve mechanical properties, then thermal effects become more non-uniform, worsening fusion evenness

Engineering Contradiction:

Improvemechanical propertiesVSAvoidfusion uniformity

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by adjusting beam thickness differently across various regions of the lattice structure. Inner beams have different thicknesses compared to outer beams, with specific thickness ranges defined for different spatial locations. This allows each region to have optimized thickness that accounts for local thermal effects, ensuring uniform fusion while maintaining manufacturing precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the beam thickness parameter based on the spatial location and thermal characteristics of different regions. By varying the thickness parameter across the lattice structure according to predefined thresholds and maps, the system achieves uniform material properties while maintaining fine lattice precision.

Inventive Principle:

Principle #35Parameter changes

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 enhances the uniformity of fusion and mechanical properties of 3D printed lattice structures, achieving target material properties by adjusting beam thicknesses according to thermal and re-radiation maps, thereby improving manufacturing quality.

Implementation Method 1

determining thermal and re-radiation maps

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

non-uniform thermal effects

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the build material may be cured or fused

Methodology Applied

Scientific EffectCuring:

Implementation Method 4

inner areas tend to be fused more than outer areas

Methodology Applied

Scientific EffectFusion:

Data Source

PatentUS20250021721A1Lattice structure thicknesses

Publication Date: 2025.01.16 PERIDOT PRINT LLC

AI summary

Examples of methods are described. In some examples, a method may include producing, by a processor, a density determination of a lattice structure. In some examples, the method may include producing, by the processor, a beam thickness determination of the lattice structure. In some examples, the method may include adjusting a beam thickness of the lattice structure based on the density determination and the beam thickness determination.