Multi-Beam Additive Manufacturing Scan Layout for Lower Residual Stress
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Solution Overview
Problem
Existing additive manufacturing methods using multiple energy beams struggle with residual stress and deformation, particularly in large and heavy components, and lack flexibility in beam arrangement.
Innovation Solution
The scanning area is divided into a central circular region and one or more ring-shaped regions, further segmented into circular segments, allowing simultaneous scanning with multiple energy beams in a predefined manner to achieve even stress distribution and symmetrical melting patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy beams are used to scan the material layer simultaneously, then productivity is improved, but residual stress and deformation increase
Solution Approach 1:
The scanning area is divided into multiple independent scanning regions (first scanning area, second scanning area, third scanning area) that are scanned sequentially rather than simultaneously. This segmentation allows the system to maintain high productivity by processing multiple regions while controlling residual stress through the specific scanning sequence and overlap design between regions.
Solution Approach 2:
The patent implements periodic scanning patterns where scanning beams repeatedly traverse the material layer in defined sequences. The scanning process uses periodic back-and-forth motion patterns with overlapping regions, creating a rhythmic heating and cooling cycle that helps distribute thermal stress more uniformly across the build area, thereby reducing deformation while maintaining efficient processing speed.
2Manufacturing precision
If the scanning area is divided into multiple regions for simultaneous scanning, then manufacturing precision can be improved, but device complexity increases
Solution Approach 1:
The patent employs multiple scanning beams that can be dynamically assigned to different scanning regions and patterns. The same set of scanning beams serves multiple functions by adjusting their trajectories and scanning sequences, rather than requiring dedicated beams for each region. This multi-functionality reduces device complexity while maintaining the capability to scan multiple areas with high precision.
Solution Approach 2:
The scanning system uses dynamic control of beam trajectories and scanning sequences rather than fixed, static beam assignments. The scanning beams can adapt their paths in real-time based on the defined component geometry and the required scanning pattern, allowing the system to achieve high manufacturing precision without requiring a permanently complex device configuration for each specific scan pattern.
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 minimizes residual stress and deformation in manufactured components, especially for large and heavy parts, while providing flexibility in energy beam arrangement.
Implementation Method 1
an energy beam device that is adapted and configured to provide two or more energy beams and to scan the layer of material with the two or more energy beams... scanning the layer of material with the two or more energy beams to melt the material according to the defined component configuration
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a method for additive manufacturing a component comprising the steps of - defining a configuration for a component, - providing a layer of material, - providing an energy beam device that is adapted and configured to provide two or more energy beams and to scan the layer of material with the two or more energy beams over a scanning area, - scanning the layer of material, wherein the scanning area (1) is divided into a central circular region (3) and at least one ring-shaped region (4-8) and in that the regions (3-8) are scanned in a predefined manner, or in that the central circular region (3) and/or one or more ring-shaped regions (4-8) are each further divided into two or more segments (9-14), and the segments (9-14) and/or one or more non-divided regions are scanned in a predefined manner. Furthermore, the invention relates to a system for additive manufacturing a part.