Layer Imaging Control for Adaptive Additive Manufacturing Settings
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Solution Overview
Problem
Additive manufacturing (AM) processes face challenges in achieving both high-quality components and efficient production due to issues like excessive energy application leading to internal stress, deformation, and porosity, particularly in regions with varying cross-sectional areas.
Innovation Solution
The use of thermal imaging to adjust parameters such as layer thickness and high energy beam settings in real-time, based on topographical characteristics, to optimize energy application and layer formation, allowing for adaptive control of powder deposition and beam settings during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If uniform layer thickness is used throughout the build, then manufacturing simplicity is maintained, but production efficiency decreases due to unnecessarily slow processing in thicker regions
Solution Approach 1:
The patent applies local quality by varying the layer thickness parameter across different spatial regions of the build platform. Specifically, the controller is configured to set a first layer thickness for a first region and a second layer thickness for a second region, where the thicknesses differ based on local requirements. This allows thinner layers in regions requiring higher precision or slower cooling rates, while enabling thicker layers in regions that can tolerate faster processing, thereby optimizing overall production efficiency without compromising part quality.
2Manufacturing precision
If higher energy density is applied to thicker sections, then layer consolidation improves, but internal stress and deformation increase
Solution Approach 1:
The patent implements local quality by spatially varying the energy density parameters across different regions of the build platform. The controller adjusts at least one energy beam parameter (such as power, scan speed, or hatch spacing) based on the identified first and second regions. This enables higher energy density to be applied selectively to thicker sections that require better consolidation, while lower energy density is applied to thinner regions to prevent excessive heat input, internal stress, and deformation.
Solution Approach 2:
The patent applies dynamics by making the energy beam parameters adjustable and adaptive during the additive manufacturing process. Rather than using fixed parameters throughout the build, the system dynamically modifies parameters such as beam power, scan speed, or hatch spacing based on real-time or pre-planned regional requirements. This dynamic adjustment allows optimal energy density to be applied to each region, balancing layer consolidation quality with minimization of thermal stress and deformation.
3Manufacturing precision
If smaller layer thickness is used for all layers, then quality issues in thin sections are avoided, but production throughput decreases
Solution Approach 1:
The patent resolves this contradiction by applying local quality principles to layer thickness control. The system identifies different regions on the build platform and assigns appropriate layer thickness values to each region. Thin sections are built with smaller layer thickness to ensure quality and avoid defects, while thicker regions utilize larger layer thickness to maintain acceptable quality standards. This regional differentiation allows the build process to proceed at higher overall throughput while still meeting quality requirements for critical thin sections.
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 quality of AM components by reducing internal stress and porosity while improving production efficiency by optimizing energy distribution and layer formation.
Implementation Method 1
A thermal imaging device, such as an infrared camera, may take an image, e.g., a digital thermal image, of the first formed layer
Implementation Method 2
The first layer of material may be selectively heated, e.g., sintered or melted, by a high energy beam applied by the AM machine
Implementation Method 3
The first layer of material may be selectively heated, e.g., sintered or melted, by a high energy beam applied by the AM machine to form a first formed layer
Implementation Method 4
Ejected droplets coalesce and solidify upon reaching the substrate or formed layers to form a build structure layer by layer
Data Source
AI summary
A fabrication of a build structure by an additive layer manufacturing machine is assessed and controlled. A first portion of a first material is selectively heated to form a first formed layer of the build structure having a first thickness. An image of a predefined region of the first formed layer is generated. The image depicts topographical characteristics within the predefined region of the first formed layer. A subsequent portion of the first or a second material is selectively heated to form a subsequent formed layer of the build structure attached to the first formed layer. The subsequent formed layer has a second thickness that correlates with the depicted topographical characteristics.