Modulated Scanning Trajectory for Additive Manufacturing Productivity
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Solution Overview
Problem
Conventional additive manufacturing devices have insufficient productivity due to limitations in energy distribution and melt pool control, leading to inefficiencies and increased costs when attempting to enhance productivity by using multiple laser sources.
Innovation Solution
The introduction of a modulation device that modifies the scanning trajectory of a single laser source, allowing for a secondary trajectory to be superimposed on the main trajectory, thereby improving energy distribution and melt pool control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of laser sources is increased to improve productivity, then the manufacturing speed increases, but the device complexity and cost increase significantly
Solution Approach 1:
The patent applies dynamics by making the scanning trajectory dynamic through superimposition of a secondary trajectory on the main trajectory. This allows a single laser source to cover a larger effective area by modulating its path, achieving productivity improvement without increasing the number of laser sources. The modulation frequency and amplitude can be adjusted to optimize the balance between manufacturing speed and energy distribution.
Solution Approach 2:
The patent introduces another dimension by adding a secondary trajectory dimension to the main scanning trajectory. This creates a two-dimensional modulation space that allows the single laser beam to effectively cover a larger area through composite motion patterns, resolving the contradiction between using multiple lasers and maintaining device simplicity.
2Productivity
If multiple laser sources are used to increase productivity, then the manufacturing efficiency improves, but the space requirements and system complexity increase
Solution Approach 1:
By dynamically modulating the scanning trajectory of a single laser source through superimposition of secondary trajectories, the system achieves the effective coverage area of multiple static laser sources without requiring additional physical space for multiple laser units and their associated optics.
Solution Approach 2:
The single laser source performs multiple functions by executing different trajectory patterns (main trajectory plus superimposed secondary trajectory), effectively replacing the roles of multiple laser sources while reducing the overall system footprint and space requirements.
3Productivity
If multiple laser sources are implemented to enhance productivity, then the output increases, but the manufacturing cost increases
Solution Approach 1:
The dynamic trajectory modulation approach uses a single laser source with controlled motion patterns, eliminating the need to purchase, install, and maintain multiple expensive laser systems. The cost increase is limited only to the control system for trajectory modulation, which is significantly cheaper than multiple laser sources.
Solution Approach 2:
Instead of physically replicating multiple laser sources, the system creates a virtual copy effect through trajectory superimposition, where the single laser beam follows composite paths that simulate the coverage area of multiple lasers, thereby avoiding the high costs associated with multiple hardware units.
4Manufacturing precision
If the scanning trajectory is modified to improve energy distribution, then the melt pool control improves, but the system complexity increases
Solution Approach 1:
The system achieves improved melt pool control through dynamic trajectory modulation, where the secondary trajectory is superimposed on the main trajectory. This allows real-time adjustment of energy distribution patterns without adding complex hardware, as the modulation can be controlled through software algorithms that generate the appropriate motion patterns.
Solution Approach 2:
By changing the parameters of the scanning trajectory (amplitude, frequency, phase of the secondary trajectory), the system optimizes energy distribution and melt pool characteristics. This parameter-based control approach improves manufacturing precision without requiring complex structural modifications to the system.
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 efficiency of energy transfer to the material, increases the melt flow rate, and improves the metallurgical state of the formed material, while maintaining a compact and cost-effective device.
Implementation Method 1
The source 110 may be a radiation source, for example a laser source, for example adapted to emit a laser beam
Implementation Method 2
enhances the efficiency of energy transfer to the material
Implementation Method 3
The device 120 may comprise a mirror 121, for example adapted to reflect the laser beam coming from the laser source and/or direct it towards the scanning device. The angle α of incidence of the laser beam coming from the laser source on the mirror 121 is between 20 and 45°
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
Apparatus for manufacturing a three-dimensional object by selective additive manufacturing, comprising: - a holder (140) suitable for holding at least one layer (150) of additive-manufacturing powder, - a laser source (110) suitable for emitting a laser beam (111), - a scanning device (130) suitable for directing the laser beam over the powder layer so as to scan at least one portion of the powder layer, - a device (120) for modulating the scanning path, said device being placed upstream of the scanning device, the modulating device comprising a modulating mirror (121) suitable for reflecting the laser beam output from the laser source and for directing it toward the scanning device, the angle of incidence of the laser beam output by the laser source on the modulating mirror being comprised between 20 and 45°.