Multi-Beam 3D Printing Seam Offset for Stronger Fused Layers
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Solution Overview
Problem
Three-dimensional printing systems using multiple energy beams face challenges in transitioning between energy beams, affecting the internal structural integrity of fabricated articles due to alignment uncertainties and seam inconsistencies.
Innovation Solution
A three-dimensional printing system employing multiple energy beams, where a controller coordinates the operation of multiple lasers to form composite hatch patterns with offset seams and varying transverse overlap distances, ensuring robust structural integrity by independently scanning and fusing metal powder layers with precise alignment and overlapping strategies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy beams are used to increase productivity, then manufacturing speed and output are improved, but alignment uncertainties and seam inconsistencies worsen, affecting internal structural integrity
Solution Approach 1:
The patent applies preliminary action by pre-planning the scanning paths of multiple energy beams to ensure they converge at predetermined seam locations. The controller is configured to coordinate the beams in advance, calculating optimal transverse overlap distances and offset patterns before fabrication begins, thereby eliminating alignment uncertainties that would otherwise occur during real-time operation.
Solution Approach 2:
The patent implements local quality by varying the transverse overlap distance of beam seams at different locations and layers. Instead of using a uniform overlap distance throughout the fabrication process, the system optimizes the overlap distance locally at each seam location based on the specific geometric and structural requirements of that region, thereby maintaining high precision while accommodating the complexity of multiple beams.
2Loss of time
If multiple energy beams operate simultaneously to reduce fabrication time, then productivity increases, but seam consistency and structural integrity deteriorate due to coordination challenges
Solution Approach 1:
The patent applies dynamics by implementing a coordinated control system that dynamically adjusts the scanning paths and timing of multiple energy beams during fabrication. The controller continuously synchronizes the beams' movements and ensures they converge at the correct seam locations in real-time, allowing simultaneous operation while maintaining seam consistency and structural integrity throughout the process.
3Ease of operation
If simple beam transition strategies are used to maintain ease of operation, then operational simplicity is preserved, but internal structural integrity and seam quality worsen
Solution Approach 1:
The patent implements parameter changes by systematically varying the transverse overlap distance parameter at different seam locations and layers. The controller adjusts this parameter based on pre-calculated optimal values for each region, transforming a potentially complex multi-parameter problem into a manageable single-parameter optimization that maintains both ease of operation and high structural integrity.
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 system enhances the internal structural integrity of 3D articles by minimizing alignment errors and optimizing seam patterns, resulting in stronger and more consistent fabrication across layers.
Implementation Method 1
directing a first energy beam from a first energy beam source over said work table, said directing of said first energy beam causing said first powder layer to fuse
Implementation Method 2
Each layer of powdered material is selectively fused using an energy beam such as a laser
Data Source
Figure 1~2
Figure 3A~3D
Figure 4~5
AI summary
A system for fabricating a three-dimensional article (2) includes a powder dispenser (14) and a fusing apparatus (16). The fusing apparatus is configured to generate and scan a plurality of beams (18) across a build plane including a first beam and a second beam. The controller (20) is configured to operate the powder dispenser and the fusing apparatus to form a sequence of at least three fused layers. The layers individually include a first hatch area (26) defined by the first energy beam and a second hatch area (28) defined by the second energy beam. The first and second hatch areas overlap along a seam (30) with a transverse overlap distance (x). A lateral location of the seam varies layer by layer. No two layers in the sequence have a transverse distance between seams of less than u. The distance u is at least equal to twice the transverse overlap distance.