Multi-Beam Additive Manufacturing Control Against Gas Flow
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Solution Overview
Problem
Existing additive manufacturing processes using multi-beam devices face challenges in uniformly utilizing all beam sources, preventing collisions of smoke plumes, and avoiding spatter particles from being melted in during the solidification process.
Innovation Solution
A control method for a multi-beam device that divides the material to be solidified into sections, controls the points of impact of the beams against the gas flow direction, and ensures that beams operate within a predetermined distance from each other to avoid interference, using a scanning strategy that optimizes beam utilization and prevents spatter melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple beams are used to solidify material simultaneously, then productivity increases, but smoke plumes from different beams may collide and interfere with each other
Solution Approach 1:
The build area is divided into multiple sections, with each section assigned to a specific beam. This segmentation ensures that beams operate in dedicated zones, preventing smoke plume collisions while maintaining simultaneous multi-beam operation for high productivity
Solution Approach 2:
The patent introduces spatial arrangement of beams at different angles and positions, utilizing three-dimensional space to distribute beams throughout the build volume. This dimensional distribution prevents smoke plume interference while maximizing parallel processing capability
2Productivity
If beams are positioned close together to maximize material utilization, then manufacturing efficiency improves, but spatter particles from one beam may be melted by adjacent beams
Solution Approach 1:
The build area is divided into sections with defined boundaries, creating spatial separation between beams. This segmentation allows beams to operate close together for high efficiency while maintaining sufficient distance to prevent spatter particle interference between adjacent beams
Solution Approach 2:
Different regions of the build area are assigned to specific beams based on local requirements. Each beam operates with optimized parameters for its designated zone, allowing close spacing for efficiency while maintaining local control to prevent spatter melting in adjacent regions
3Productivity
If all beam sources are utilized uniformly, then manufacturing speed increases, but some beams may interfere with the gas flow required for smoke removal
Solution Approach 1:
The build area is segmented into sections that are strategically assigned to beams based on gas flow patterns. This segmentation ensures uniform beam utilization while positioning beams to avoid blocking gas flow paths, maintaining effective smoke removal throughout the build volume
Solution Approach 2:
Beam positions and orientations are dynamically optimized to adapt to gas flow conditions. The system adjusts beam configurations to maintain uniform utilization while ensuring gas flow channels remain unobstructed for effective smoke evacuation
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
The method ensures efficient and uniform utilization of all beam sources, prevents collisions and spatter interference, and improves the quality and efficiency of three-dimensional workpiece manufacturing by minimizing smoke plume interactions and spatter impact.
Implementation Method 1
The irradiation can be carried out using electromagnetic radiation, in particular laser radiation, or particle radiation
Implementation Method 2
solidify it by site-specific irradiation, e.g., by melting or sintering
Implementation Method 3
solidify it by site-specific irradiation, e.g., by melting or sintering
Implementation Method 4
a gas flow used for removing soot generated during the solidification of the material to be solidified by the beams
Data Source
Figure 1
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AI summary
Control method for controlling a multi-beam device with one or more beam sources for generating multiple beams of a system for manufacturing a three-dimensional workpiece by means of an additive layer manufacturing process, in which a solidifiable material for manufacturing the three-dimensional workpiece is applied layer by layer to a surface of a support and the solidifiable material in each layer is solidified at the respective points of impact of the multiple beams on the solidifiable material by the multiple beams,wherein the points of impact of the jets for solidifying selective areas of one of the layers of the material to be solidified for the production of the three-dimensional workpiece are controlled substantially against a gas flow direction over the surface of the support; wherein the control method comprises: (a) dividing the material to be solidified in the respective layer into at least two sections, wherein two of the at least two sections extend at least partially one behind the other in the gas flow direction prevailing over the two of the at least two sections, (b) dividing at least one of the two of the at least two sections into at least two surface areas, (c) assigning each of the surface areas to exactly one specific jet which solidifies the material to be solidified in the assigned surface area, (d) controlling the points of impact of the jets such that,that at least at one point during exposure of the material to be solidified, the material to be solidified is solidified in at least two surface areas, and that a network of straight lines running between each center point of the impact points to each other center point of the impact points does not, at any point during exposure in which all centers of the impact points are outside a predetermined distance from each other, exhibit a straight line parallel to the direction of the gas flow prevailing over the two of the at least two sections.