Multi-Beam Irradiation Planning for Reproducible Powder Bed Fusion
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Solution Overview
Problem
Current methods for selectively irradiating working areas using multiple energy beams in additive manufacturing lack reproducibility and predictability, especially in aerospace engineering where quality and safety standards are stringent, often resulting in imperfections or pores due to unclear beam assignments.
Innovation Solution
A method for planning locally selective irradiation by assigning energy beams to test vectors based on predefined borders in the working area, using rules such as the 'greater-portion rule' and 'transcending rule' to ensure predictable and reproducible beam assignments, avoiding hard boundaries and simplifying the process without high processing power demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy beams are displaced simultaneously along different irradiation vectors to accelerate manufacturing, then productivity is improved, but reliability deteriorates because beam assignment becomes unpredictable and non-reproducible
Solution Approach 1:
The patent applies preliminary action by pre-defining borderlines in the working area before the irradiation process begins. These borderlines establish predetermined regions that assign specific energy beams to specific areas. This pre-planning ensures that during simultaneous multi-beam irradiation, each beam's path and target region are known in advance, making the process reproducible and suitable for certified manufacturing while maintaining high productivity
2Reliability
If algorithms are designed to ensure reproducible beam assignment, then reliability is improved, but device complexity increases due to high processing power demands
Solution Approach 1:
The patent applies segmentation by dividing the working area into distinct regions using predefined borderlines. Each region is associated with a specific energy beam. This spatial segmentation simplifies the assignment logic compared to complex algorithms, as each beam only needs to follow its assigned region's contours. The segmentation approach ensures reproducible beam assignment while avoiding high processing power demands by using simple geometric region definitions rather than complex computational algorithms
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 allows for predictable and reproducible beam assignments, enhancing the manufacturing of certified objects by avoiding imperfections and pores, while simplifying the process and reducing processing power requirements.
Implementation Method 1
selectively irradiating a working area with a plurality of energy beams to solidify or consolidate powder material
Implementation Method 2
which laser will be assigned to which region
Data Source
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AI summary
The invention relates to a method for planning a locally selective irradiation of a working area (7) with a plurality of energy beams (11) by displacing the plurality of energy beams (11) along a plurality of irradiation vectors (15) over a powder material layer (6) of a powder material (5) arranged in the working area (7), comprising: i) assigning an energy beam (11) of the plurality of energy beams (11) to at least one test vector (29), the test vector (29) comprising at least one irradiation vector (15) of the plurality of irradiation vectors (15), on the basis of at least one property of the test vector (29) with respect to a predefined borderline (21) in the working area (7), and ii) obtaining an irradiation plan.