3D Microtechnology Printing with Dual Laser Solidification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing three-dimensional objects in microtechnology, such as those using pulsed laser radiation, often result in parts with residual porosity, making them unsuitable for certain microtechnology applications.
Innovation Solution
A method involving the successive solidification of single layers of a liquid or powdery building material using a combination of first and second pulsed electromagnetic radiation, where the second radiation has a higher frequency or is continuous, to enhance density and mechanical properties of the manufactured components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pulsed laser radiation is used for manufacturing three-dimensional objects, then the manufacturing process can be controlled, but residual porosity occurs in the parts
Solution Approach 1:
The manufacturing process is segmented into two distinct irradiation steps: a first pulsed laser irradiation step and a second continuous or high-frequency pulsed laser irradiation step. This segmentation allows each step to perform a specific function - the first step provides controlled solidification while the second step eliminates porosity, thereby resolving the contradiction between process control and part reliability
Solution Approach 2:
The invention transitions from purely pulsed irradiation to a combination that includes continuous or high-frequency pulsed irradiation. The continuous action in the second step ensures complete densification and elimination of residual porosity, while the initial pulsed action maintains manufacturing control, thus achieving both reliability and controllability
2Device complexity
If single frequency pulsed electromagnetic radiation is used, then the process is simple, but the mechanical properties and density of manufactured components are insufficient
Solution Approach 1:
The invention merges two different types of electromagnetic radiation (pulsed and continuous/high-frequency pulsed) into a single manufacturing process. This combination allows the first radiation type to perform initial solidification while the second radiation type enhances density and mechanical properties, resolving the contradiction between process simplicity and component strength
Solution Approach 2:
The invention changes the parameters of electromagnetic radiation by using two distinct frequency regimes and temporal patterns. The first pulsed radiation operates at lower frequency for controlled solidification, while the second continuous or high-frequency radiation provides the energy density needed for optimal mechanical properties, thus achieving high strength without excessive process complexity
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 enables the production of three-dimensional components with improved density and mechanical properties, suitable for microtechnology applications, by controlling energy input and reducing stresses in the layers through the combination of different radiation frequencies.
Implementation Method 1
the object is generated by successively solidifying of single layers of a liquid or powdery solidifiable building material by the action of electromagnetic radiation
Implementation Method 2
laser sintering or laser melting is used
Implementation Method 3
a micro laser sintering (micro-LS) process, by which three-dimensional objects, with a resolution in the range of micrometers, are built-up
Data Source
AI summary
The present invention relates to a method and a device for manufacturing a three-dimensional object, wherein the object is generated by successively solidifying single layers of fluid or powdery solidifiable building material by the action of electromagnetic radiation. The method comprises steps for emitting a first pulsed electromagnetic radiation onto a first area of a layer of the building material, and for emitting a second continuous electromagnetic radiation onto a second area of the layer of the building material.