Multi-Beam Build Plate Zoning for Faster Parallel Part Production
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Solution Overview
Problem
Existing additive manufacturing systems require significant setup time to adjust multiple energy sources and material supplies for accurate positioning on a build surface, leading to inefficiencies in producing multiple copies of the same component.
Innovation Solution
A forming system with a build plate segregated into non-overlapping zones, each associated with a high-energy beam provider, and using datums to ensure accurate alignment and separation of components, allowing simultaneous energy application and easy separation of build zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy sources and material supplies are used to build multiple components simultaneously, then productivity is improved, but setup time and device complexity increase significantly
Solution Approach 1:
The build plate is divided into multiple non-overlapping build zones, with each zone associated with a dedicated energy source and material supply. This segmentation allows each zone to be independently configured and processed, enabling simultaneous production of multiple components without requiring complex coordination between shared resources.
Solution Approach 2:
Datums are provided on the build plate at known locations before component manufacturing begins. These datums establish predetermined reference points that enable automatic alignment and positioning of energy sources and material supplies, eliminating the need for time-consuming manual adjustment and setup of each energy source.
2Adaptability or versatility
If multiple energy sources are moved independently to build separate components, then manufacturing flexibility is improved, but positioning accuracy and alignment precision deteriorate
Solution Approach 1:
The system uses datums as reference points that provide feedback for positioning and alignment. By referencing known datum locations on the build plate, the system can automatically correct and verify the position of each energy source, ensuring consistent positioning accuracy regardless of independent movement or configuration.
3Device complexity
If multiple energy sources share a common traversal actuator, then device complexity is reduced, but productivity and flexibility worsen due to sequential operation requirements
Solution Approach 1:
Instead of sharing a common traversal actuator, the system segments the motion control by associating each energy source with its own traversal actuator. This allows each energy source to move independently to its designated build zone, enabling simultaneous operation and eliminating the sequential bottlenecks that would result from shared actuator control.
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
Facilitates efficient production of multiple components with precise alignment and separation, reducing setup time and enhancing manufacturing density and safety.
Implementation Method 1
Each high-energy beam provider may generate a laser beam, electron beam or other high-energy beam capable of melting the material used to form the one or more datums and the one or more articles
Implementation Method 2
Each high-energy beam provider may generate a laser beam, electron beam or other high-energy beam capable of melting the material used to form the one or more datums and the one or more articles
Implementation Method 3
A laser or other high energy source traverses over the layer of powder to selectively melt portions
Implementation Method 4
Each high-energy beam provider may comprise a mirror or other reflecting device to reflect a laser beam, electron beam or other high-energy beam capable of melting the material
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
A method of forming a plurality of components on a build-plate, the method comprising the steps of providing a forming system comprising a plurality of high-energy beam generators mounted on a common support and configured to direct energy onto the build-plate; the build-plate comprising at least one segregation zones segregating the build plate into a plurality of build zones, each build zone associated with one of the high-energy beam generators; forming within each build zone at least one datum from material melted by energy from its associated high-energy beam generator; and forming within each build zone at least one component from material melted by energy from its associated high-energy beam generator; cutting or machining the build plate at the segregation zone or segregation zones to separate the build zones.