Multi-Beam 3D Printing via Subordinate File Parallelization

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Solution Overview

Problem

Conventional additive manufacturing methods, such as direct metal laser melting (DMLM), become unacceptably long for manufacturing large or complex objects due to the sequential processing of 3D layers, which hampers efficiency and productivity.

Innovation Solution

Dividing a master 3D model file into subordinate files, each representing a portion of the object, allowing for parallel processing using multiple lasers, which can emit different wavelengths and powers, to fabricate corresponding portions simultaneously.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional additive manufacturing processes are used to manufacture large or complex objects, then manufacturing precision and material quality are maintained, but fabrication time becomes unacceptably long

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidfabrication time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent divides a single large 3D model file into multiple smaller subordinate files, each representing a portion of the object. This segmentation enables parallel processing of multiple regions simultaneously, dramatically reducing fabrication time while maintaining manufacturing precision through consistent laser parameters across all segments

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from sequential single-beam processing to parallel multi-beam processing by introducing multiple lasers operating simultaneously on different portions of the object. This dimensional expansion from one processing stream to multiple concurrent streams reduces fabrication time without compromising quality

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If sequential layer-by-layer processing is used, then manufacturing quality is maintained, but productivity decreases

Engineering Contradiction:

Improvemanufacturing qualityVSAvoidproductivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

By segmenting the object into multiple portions with separate subordinate files, the system can process multiple segments in parallel while maintaining the same quality standards for each segment, thereby increasing overall productivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses multiple lasers with identical or complementary functionality to process different portions of the object simultaneously. Each laser performs the same manufacturing function on its assigned segment, enabling parallel processing that boosts productivity while maintaining consistent quality across all portions

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If single laser processing is used, then device complexity is low, but manufacturing speed is slow

Engineering Contradiction:

Improvedevice complexityVSAvoidmanufacturing speed

Core Design Contradiction:

Device complexityVSSpeed

Solution Approach 1:

The processing task is segmented across multiple lasers, with each laser handling a specific portion of the object. This distribution of workload increases manufacturing speed while the complexity increase is managed through automated file division and coordinated control systems

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by pre-dividing the master file into subordinate files and assigning them to specific lasers before processing begins. This preparation enables seamless parallel processing and maximizes manufacturing speed from the outset without requiring complex real-time coordination

Inventive Principle:

Principle #10Preliminary action

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 increases manufacturing speed and data organization, particularly for larger objects, by enabling simultaneous processing of multiple layers, thus optimizing the production of complex parts and reducing overall fabrication time.

Implementation Method 1

A particular type of AM process uses electromagnetic radiation such as a laser beam, to solidify or cure a liquid photopolymer, creating a solid three-dimensional object

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

direct metal laser melting (DMLM), selective laser melting (SLM)

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS11796981B2Parallelized fabrication using multi beam additive printing of subordinate files

Publication Date: 2023.10.24 GENERAL ELECTRIC CO

AI summary

The present disclosure generally relates to additive manufacturing or printing of an object using parallel processing of files comprising 3D models of the object and/or portions thereof. A master file comprising a 3D model of the object is divided into subordinate files, wherein each subordinate file comprises a 3D model of a corresponding portion of the object. Each subordinate file is processed in parallel, controlling at least a first laser source to fabricate each portion from a build material. Parallel processing according to the methods of the present disclosure expedites additive manufacturing or printing over conventional methods that build an object in layers completed in series.