Multi-Beam 3D Printing Temperature Control for High-Melting Materials

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Solution Overview

Problem

Existing devices for additive production of three-dimensional objects lack effective temperature control, particularly for high melting point materials, as they cannot pre-dry materials or provide local temperature control, restricting processing to low temperature thresholds and leading to issues like gas porosity and thermal stress.

Innovation Solution

A device with multiple irradiation devices, including laser and electron beam systems, controlled by a sophisticated control unit to generate and direct energy beams for selective solidification and temperature control, allowing for precise local heating and cooling of construction material layers, enabling the processing of high melting point materials and reducing thermal stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heating elements are used for temperature control, then temperature control is provided, but pre-drying and local temperature control are not enabled

Engineering Contradiction:

Improvetemperature control capabilityVSAvoidpre-drying and local temperature control functionality

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The patent replaces traditional mechanical heating elements with an electron beam system for temperature control. The electron beam can be precisely directed to specific locations on the construction material, enabling both overall heating and localized temperature control, as well as pre-drying of material layers before solidification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electron beam system serves multiple functions: it can perform pre-drying of hygroscopic materials, provide localized heating in specific regions, control overall temperature distribution, and enable solidification of construction material. This single system replaces what would otherwise require separate heating elements and drying mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If heating elements are used for temperature control, then temperature control is provided, but processing of high melting point materials is restricted

Engineering Contradiction:

Improvetemperature control capabilityVSAvoidprocessing capability for high melting point materials

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The electron beam system allows for dynamic adjustment of beam energy, current, and focal spot size to achieve the extremely high temperatures required for melting and processing high melting point materials. The beam parameters can be precisely controlled and modified during the additive manufacturing process to match the specific requirements of different materials.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If conventional heating elements are used, then temperature control is provided, but energy consumption is high and thermal stress increases

Engineering Contradiction:

Improvetemperature control capabilityVSAvoidenergy consumption and thermal stress

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The electron beam delivers energy precisely to the specific location where construction material needs to be heated or melted, rather than heating the entire construction chamber uniformly. This localized energy delivery reduces overall energy consumption and minimizes thermal gradients that cause stress in the constructed object.

Inventive Principle:

Principle #3Local quality

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 solution enables selective and local temperature control, reducing energy consumption and thermal stress, improving the structural properties of produced objects by allowing precise control over melting and solidification conditions, and minimizing gas porosity and thermal gradients.

Implementation Method 1

selective irradiation and accompanying successive, layered, selective solidification of construction material layers

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Implementation Method 2

successive, layered, selective irradiation and accompanying successive, layered, selective solidification of construction material layers

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

construction material that can be solidified by means of an energy beam

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11911959B2Device for additive production of three-dimensional objects

Publication Date: 2024.02.27 CONCEPT LASER

AI summary

A device (1) for the additive production of three-dimensional objects (2) by successive, layered, selective irradiation and accompanying successive, layered, selective solidification of construction material layers of a construction material (3) that can be solidified by means of an energy beam, comprising: a plurality of irradiation devices (6 and 7), which are designed to generate an energy beam, a control device (16), which is designed to generate control information controlling the operation of the irradiation devices (6 and 7) and to control the operation of the irradiation devices (6 and 7) on the basis of generated control information, wherein the control device (16) is designed to generate first control information in order to control the operation of a first irradiation device, on the basis of which the first irradiation device generates a first energy beam (4a) for the successive, layered, selective solidification of a construction material layer.