Metal Additive Build Contours With Wave Infill Rate Control
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Solution Overview
Problem
Conventional additive manufacturing processes are slow and inadequate for producing certain types of parts, such as tools, due to long build times and inefficiencies in layer deposition rates.
Innovation Solution
The implementation of a system that includes a metal deposition device and a controller to manage contour and infill patterns in additive manufacturing, where the deposition rate is adjusted to improve efficiency and accuracy, with techniques like wave-shaped infill patterns and energy application at crossover points to fuse materials without distorting the contour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional additive manufacturing processes are used to deposit metal material layer-by-layer, then manufacturing precision and part quality are maintained, but build time is excessively long and productivity is low
Solution Approach 1:
The additive manufacturing process is segmented into two distinct phases: contour deposition phase (deposition rate of 0.5-5 mm/min) and infill pattern deposition phase (deposition rate of 5-50 mm/min). This segmentation allows each phase to be optimized independently - the contour phase ensures precision for critical dimensions while the infill phase maximizes deposition speed for bulk material, thereby resolving the contradiction between build time and part quality
Solution Approach 2:
The system dynamically adjusts the deposition rate based on the current manufacturing phase and location. The controller automatically switches between slow contour deposition and fast infill deposition, and further adjusts parameters when transitioning between patterns or layers. This dynamic adaptation enables the system to maintain high precision where needed while achieving overall productivity improvement
2Productivity
If high deposition rate is used to reduce build time, then productivity improves, but manufacturing precision and part quality deteriorate
Solution Approach 1:
Different deposition rates are applied to different regions of the part based on quality requirements. The contour regions (which define critical dimensions and surfaces) receive slow deposition (0.5-5 mm/min) to ensure high precision, while the infill regions (which provide bulk support) receive fast deposition (5-50 mm/min). This local differentiation resolves the contradiction by applying high speed only where it doesn't compromise quality
Solution Approach 2:
The deposition process is divided into contour deposition and infill deposition segments with distinctly different speed requirements. By separating these functions and assigning appropriate deposition rates to each, the system achieves both high precision in critical areas and high productivity in non-critical areas
3Productivity
If infill pattern deposition rate is increased to improve efficiency, then productivity improves, but distortion at crossover points increases
Solution Approach 1:
The system employs periodic modulation of deposition parameters during infill pattern deposition. When the deposition head approaches crossover points (where infill patterns intersect with contours), the controller temporarily reduces deposition rate or adjusts energy input in a periodic cycle. This periodic adjustment prevents excessive heat accumulation and material distortion at critical intersection points while maintaining high overall deposition speed
Solution Approach 2:
The controller monitors deposition parameters and part geometry in real-time, detecting when the deposition head is approaching crossover points. Based on this feedback, the system automatically adjusts deposition rate and energy input to prevent distortion, then returns to high-speed deposition once the crossover point is passed. This closed-loop control resolves the contradiction by dynamically responding to actual process conditions
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 significantly reduces build times and enhances the quality and performance of 3D parts by optimizing deposition rates and precision, particularly suitable for complex and tool-like structures.
Implementation Method 1
The power source and the laser are configured to provide energy to melt at least the filler wire during the additive manufacturing process
Implementation Method 2
a laser operatively connected to the power source. The power source and the laser are configured to provide energy to melt at least the filler wire
Implementation Method 3
the controller is configured to command the metal deposition device to fuse the metal material of the infill pattern to the metal material of the contour at crossover points, where the infill pattern meets the contour, by applying energy at the crossover points
Implementation Method 4
a non-consumable electrode operatively connected to the power source. The power source and the non-consumable electrode are configured to provide energy to melt at least the filler wire during the additive manufacturing process by forming an arc between the non-consumable electrode and the base
Implementation Method 5
a second wire feeder operatively connected to the power source and configured to feed a consumable wire electrode of the metal material toward the base. The power source is configured to provide energy to melt at least the consumable wire electrode and the filler wire during the additive manufacturing process by forming an arc between the consumable wire electrode and the base
Data Source
AI summary
Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a metal deposition device (MDD) is configured to deposit a metal material during an additive manufacturing process. A controller is operatively coupled to the MDD and is configured to command the MDD to deposit the metal material on a base to form a contour of a part. The controller is configured to command the MDD to deposit the metal material on the base to form an infill pattern within a region outlined by the contour. The infill pattern is a wave shape having a wavelength. The controller is configured to command the metal deposition device to fuse the infill pattern to the metal contour at crossover points, where the infill pattern meets the contour, by applying energy at the crossover points and reducing a deposition rate of the metal material at the crossover points to prevent distorting the contour.