Additive Manufacturing Layer Irradiation Parameter Control
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Solution Overview
Problem
Existing additive manufacturing methods for 3D objects require compromises in irradiation parameters for different structures, leading to suboptimal results or increased manufacturing time due to the need for individual parameter settings for each part.
Innovation Solution
The method involves selectively irradiating layers of a build material with different irradiation parameters, allowing for varying irradiation processes based on specific requirements of each part or structure, enabling optimal irradiation without the need for a single compromise parameter set.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single irradiation parameter is used for all parts of the object, then the manufacturing process is simplified and faster, but the surface quality and consolidation behavior of different parts cannot be optimized
Solution Approach 1:
The patent applies local quality by assigning different irradiation parameters to different parts of the object based on their specific requirements. Shell parts receive one set of parameters optimized for surface quality, while core parts receive different parameters optimized for consolidation behavior. This allows each region to be manufactured with the optimal parameters for its function, resolving the contradiction between manufacturing speed and surface quality.
Solution Approach 2:
The patent segments the object into different parts (shell parts, core parts, filigree structures) and applies different irradiation parameters to each segment. This segmentation allows the manufacturing process to optimize for different quality requirements in different regions simultaneously, maintaining productivity while improving overall manufacturing precision.
2Manufacturing precision
If individual irradiation parameters are used for each part or structure of the object, then the surface quality and consolidation behavior of different parts can be optimized, but the overall manufacturing time increases
Solution Approach 1:
The patent merges multiple irradiation parameter sets into a single integrated manufacturing process. By using a multi-parameter irradiation system that can switch between different parameter sets without stopping the process, the patent combines the benefits of optimized individual parameters with the efficiency of a continuous manufacturing process, thus reducing overall manufacturing time while maintaining high precision.
Solution Approach 2:
The patent introduces dynamic parameter adjustment during the irradiation process. The irradiation parameters are not fixed but can be changed in real-time based on the current part being manufactured. This dynamic approach allows the system to optimize for different parts without requiring separate manufacturing steps, thereby reducing total manufacturing time while maintaining high precision for each part type.
3Adaptability or versatility
If different irradiation parameters are applied to different layers, then the requirements of various structures can be met, but the process complexity increases
Solution Approach 1:
The patent implements self-service through automated parameter selection based on layer identification. The system automatically determines which irradiation parameters to apply to which layers based on pre-stored object data and layer information. This automation reduces the need for manual intervention and complex manual control systems, thereby reducing process complexity while maintaining high adaptability to different structures.
Solution Approach 2:
The patent uses feedback mechanisms where the system monitors layer completion and automatically transitions to the next layer with appropriate parameters. This feedback-driven automation allows the system to handle complex multi-parameter requirements without increasing operational complexity, as the parameter switching is managed by the control system based on real-time process state information.
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 allows for improved surface quality and reduced manufacturing time by ensuring each part or structure is irradiated with ideal parameters, without the need for changing irradiation settings during the process.
Implementation Method 1
selective irradiation via an energy beam to selectively consolidate the build material
Implementation Method 2
consolidate the build material which can be consolidated by means of an energy beam
Data Source
Figure 1
Figure 2~3
AI summary
Method for operating an apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy beam (4), wherein at least one part of a first layer (7) is irradiated based on at least one first irradiation parameter and at least one part of a second layer (8) is irradiated based on at least one second irradiation parameter, wherein the at least one first irradiation parameter and the at least one second irradiation parameter are different for the at least two layers (7, 8).