Multi-Laser Additive Manufacturing Surface Quality
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Solution Overview
Problem
In additive manufacturing using multiple laser beams, existing methods suffer from increased surface roughness due to calibration errors and drifts between laser beams, leading to inaccuracies in surface contour production.
Innovation Solution
Each individual surface contour of a component is manufactured solely by a single laser beam, ensuring that all surface contours, regardless of orientation, are exposed to the same laser beam throughout, maintaining constant accuracy and surface quality by using laser beams with identical or symmetrical focal spot sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beams are used to scan the same powder bed region, then productivity is improved by simultaneous manufacturing of different sections, but manufacturing precision deteriorates due to calibration errors and drifts between laser beams causing surface roughness increase
Solution Approach 1:
The patent segments the manufacturing task by assigning different responsibilities to multiple laser beams: one laser beam (first laser beam) is dedicated exclusively to manufacturing surface contours, while other laser beams (second laser beam(s)) manufacture internal regions or bulk material. This segmentation eliminates the calibration errors and drifts between multiple beams that previously affected surface quality, as only one beam touches the surface contour at any given time.
Solution Approach 2:
The patent applies different quality requirements to different regions of the component. Surface contours require high precision and are manufactured by a single laser beam with stable calibration, while internal regions can tolerate lower precision and are manufactured by other laser beams. This local differentiation of quality standards allows multiple beams to work simultaneously without compromising overall surface quality.
2Adaptability or versatility
If multiple laser beams with different focal spot sizes are used, then manufacturing flexibility is improved, but manufacturing precision deteriorates due to inconsistent surface quality from different focal spot sizes
Solution Approach 1:
The patent assigns different focal spot sizes to different laser beams based on their specific functions. The first laser beam, which manufactures surface contours, uses a smaller focal spot size for precision work. The second laser beam(s), which manufacture internal regions, can use larger focal spot sizes for bulk material processing. This local optimization of focal spot sizes allows manufacturing flexibility while maintaining surface quality consistency through dedicated beam assignment.
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 eliminates the impact of calibration errors and drifts between laser beams, resulting in consistent surface roughness and improved dimensional stability across the entire surface contour, allowing for simultaneous and independent manufacturing of multiple components with enhanced surface quality.
Implementation Method 1
a powder layer (metal, ceramic, thermoplastic) is applied to a substrate plate in a process chamber and solidified with a laser beam
Implementation Method 2
If the powder layer is melted by the laser beam, the manufacturing is called Laser Metal Fusion (LMF) or Selective Laser Melting (SLM)
Implementation Method 3
If the powder layer is only sintered by the laser beam, it is referred to as Selective Laser Sintering (SLS)
Data Source
AI summary
The disclosure provides methods of additive manufacture of components in layers in a powder bed by at least two laser beams that can be deflected two-dimensionally over the same powder bed region. Each laser focal spot is projected onto the power bed and is or is set to a diameter of less than or equal to 300 μm. Components to be produced in the powder bed region are manufactured by each of the laser beams, and each individual surface contour of the component is manufactured solely by one of the laser beams.