Multi-Beam Irradiation Layout for Faster 3D Layer Construction
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Solution Overview
Problem
Generative layer construction processes for producing three-dimensional workpieces are inefficient due to the need for complex optics and deflection devices, such as scanner units, which increase processing time and reduce manufacturing efficiency.
Innovation Solution
A device with a plurality of irradiation units that emit beams at a substantially constant angle, directing them onto a construction area in a matrix-like pattern, eliminating the need for scanners and allowing for simultaneous or rapid succession irradiation of individual areas, thereby reducing production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex optics and deflection devices (scanner units) are used to direct electromagnetic radiation onto predetermined areas, then selective irradiation capability is improved, but processing time increases and manufacturing efficiency decreases
Solution Approach 1:
The irradiation system is divided into multiple independent irradiation units (e.g., 7 irradiation units) that can operate simultaneously. Each unit has its own beam source and directly irradiates a specific region without requiring mechanical deflection, enabling parallel processing and significantly reducing total irradiation time while maintaining selective irradiation capability.
Solution Approach 2:
The patent replaces mechanical scanner units and beam deflection devices with a static array of multiple fixed irradiation units. Instead of mechanically moving a single beam source to scan across the workpiece, multiple stationary beam sources simultaneously irradiate different regions, eliminating mechanical complexity and increasing processing speed.
2Device complexity
If a single beam source with scanner units is used, then device complexity is reduced, but processing time increases due to sequential scanning
Solution Approach 1:
The system segments the single beam source into multiple independent beam sources (7 irradiation units), each capable of simultaneous operation. This segmentation transforms sequential scanning into parallel irradiation, dramatically reducing processing time while distributing the functional complexity across multiple simple, identical units rather than one complex scanning system.
Solution Approach 2:
The patent combines multiple simple irradiation units into a unified system that achieves the functional capability of a complex scanner. By merging multiple stationary sources that simultaneously irradiate different regions, the system achieves both reduced complexity (no moving parts) and reduced processing time (parallel operation).
3Manufacturing precision
If oscillating laser beam deflections along predetermined scan vectors are used to produce filled workpiece layers, then complete coverage is achieved, but production time increases
Solution Approach 1:
The workpiece layer coverage task is segmented across multiple irradiation units, each responsible for a specific region. Instead of one beam oscillating to cover the entire layer, 7 beams simultaneously cover different portions, achieving complete coverage much faster through parallel processing while maintaining the required manufacturing precision for filled layers.
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 improves manufacturing efficiency by allowing for rapid production of workpiece layers with reduced residual stresses and improved manufacturing quality, as individual areas can be irradiated simultaneously or in quick succession, eliminating the need for extensive beam guidance.
Implementation Method 1
The laser radiation penetrates the molding compound and solidifies it, for example as a result of heating, which causes melting or sintering
Implementation Method 2
solidifies it, for example as a result of heating, which causes melting or sintering
Implementation Method 3
solidifies it, for example as a result of heating, which causes melting or sintering
Data Source
Figure 1A~1E
Figure 2A~2C
Figure 3~3A
AI summary
The invention relates to a device (10) for producing three-dimensional workpieces, the device (10) comprising: a structural surface (14) designed to receive a moulding compound (18); and an irradiation arrangement (22) designed to selectively irradiate the moulding compound (18) on the structural surface (14) with electromagnetic radiation, in order to produce a workpiece by means of generative layer construction, where the irradiation device (22) comprises a plurality of irradiation units (28), the irradiation units (28) being designed to irradiate an individual region (32) of the structural surface respectively associated wth the irradiation units, and where the beams emitted by the irradiation units (28) respectively have a cross-sectional surface corresponding to between approx. 2% and approx. 170% of the surface of the respectively associated individual region (32). The invention also relates to the use of such a device (10) and to a method for producing three-dimensional workpieces by means of such a device (10).