Linear Laser Spot Additive Manufacturing for Large Components
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Solution Overview
Problem
Current laser additive manufacturing technologies are inefficient and costly for producing large-size components, leading to long manufacturing cycles and thermal deformation issues, limiting their application in fields like aviation and aerospace.
Innovation Solution
An additive manufacturing apparatus and method utilizing a linear light spot generated by converting a point light spot, which allows for increased scanning efficiency and uniform intensity distribution, enabling faster production of large-size components with reduced costs and thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a point light spot laser beam is used for additive manufacturing, then the light intensity distribution can be concentrated, but the manufacturing efficiency is low and the manufacturing cycle is long
Solution Approach 1:
The patent transforms the laser beam from a point light spot (0D/1D) into a line light spot (1D/2D) by introducing a cylindrical lens that focuses the laser beam in one dimension while maintaining it in the other dimension. This dimensional change allows the laser to process entire lines of powder material simultaneously rather than point-by-point, dramatically increasing the scanning speed and manufacturing efficiency for large-size components
Solution Approach 2:
The patent changes the spatial distribution parameters of the laser beam by using a cylindrical lens to create a line-shaped light spot with specific width and length parameters. This parameter transformation enables the laser to cover a larger area per scan pass, reducing the total number of scans required and thereby shortening the manufacturing cycle while maintaining precise control over the energy distribution
2Manufacturing precision
If a point light spot laser beam is used for additive manufacturing, then the precision can be maintained, but thermal deformation and thermal stress occur
Solution Approach 1:
By changing the laser beam profile from a point to a line through the cylindrical lens, the heat input is distributed along a linear path rather than concentrated at a single point. This dimensional redistribution of energy reduces the peak temperature at any single location and promotes more uniform heating, thereby minimizing thermal gradients that cause deformation and stress in large-size components
3Manufacturing precision
If a point light spot laser beam is used for additive manufacturing, then the light spot quality can be controlled, but the cost is high for large-size components
Solution Approach 1:
The cylindrical lens creates a line light spot that maintains controlled quality along its length while covering a much larger area. This allows the same laser power to process a larger volume of material in fewer passes, effectively reducing the cost per unit volume for large-size components without sacrificing the precision needed for quality control
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
The use of a linear light spot significantly increases manufacturing efficiency, reduces costs and cycles, and minimizes thermal deformation, making it suitable for large-size component production while maintaining product quality.
Implementation Method 1
a laser generating unit configured to generate a laser beam with a linear light spot for projecting on the material on the additive manufacturing platform
Implementation Method 2
A laser additive manufacturing technology is a technology for manufacturing a solid part by using a laser as a heat source to melt and stack materials such as powder materials layer by layer
Implementation Method 3
using a laser as a heat source to melt and stack materials
Implementation Method 4
a movement driving unit configured to drive at least one of the laser generating unit, the additive manufacturing platform and the material feeding unit to move or rotate in at least one direction
Data Source
AI summary
An additive manufacturing apparatus is disclosed including an additive manufacturing platform; a material feeding unit configured to feed a material onto the additive manufacturing platform; a laser generating unit configured to generate a laser beam with a linear light spot for projecting onto the material on the additive manufacturing platform; and a movement driving unit configured to drive at least one of the laser generating unit, the additive manufacturing platform and the material feeding unit to move in at least one direction. An additive manufacturing method is also disclosed. With the additive manufacturing apparatus and method, an additive manufacturing process can be performed efficiently, and are particularly suitable for an additive manufacturing process of large-size components.