Multi-Laser AM Parameter Assignment for Voxel-Level Print Control
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Solution Overview
Problem
Conventional additive manufacturing (AM) processes use a single, constant print parameter set for the entire part, leading to over-design and increased time and cost due to high-fidelity material properties being applied unnecessarily, and create transition zones when switching between different parameter sets, resulting in unpredictable material response.
Innovation Solution
A system and methodology to automatically determine and assign different print parameter sets to multiple lasers of an AM device based on analytical results, allowing for granular layer-by-layer or voxel-by-voxel adjustments, reducing or eliminating transition zones and optimizing print speed and material quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single high-fidelity print parameter set is used for the entire part, then all portions meet minimum design specifications, but production time and cost increase unnecessarily
Solution Approach 1:
The patent applies local quality by assigning different print parameter sets to different regions of the part based on their specific requirements. The system divides the part into multiple regions, each with its own optimized parameters, allowing high-fidelity parameters to be used only where necessary while using standard parameters in other areas, thus resolving the contradiction between reliability and productivity.
Solution Approach 2:
The patent segments the part into multiple regions with different print parameter requirements. By dividing the build volume into distinct zones and assigning appropriate parameter sets to each zone, the system avoids applying high-fidelity parameters globally, thereby reducing production time while maintaining design specifications in critical areas.
2Productivity
If print parameters are changed during printing, then optimization for different part portions is achieved, but transition zones with unpredictable material response are created
Solution Approach 1:
The patent uses transition layers as intermediary zones between regions with different print parameters. These transition layers gradually adjust the material properties and process conditions, preventing abrupt changes that would create unpredictable material response. The intermediary transition layers ensure smooth parameter transitions while maintaining material consistency.
Solution Approach 2:
The patent performs preliminary planning of parameter transitions by pre-defining transition layers and their properties before printing begins. This preliminary action ensures that parameter changes occur in a controlled and predictable manner, avoiding unexpected material responses during the printing process.
3Productivity
If multiple print parameter sets are used, then production efficiency increases, but system complexity increases
Solution Approach 1:
The patent implements self-service through automated parameter assignment systems that automatically select and apply the appropriate print parameter set for each region based on pre-defined criteria. This automation reduces the manual complexity of managing multiple parameter sets while maintaining the productivity benefits of region-specific optimization.
Solution Approach 2:
The patent systematically manages parameter changes by establishing clear rules and criteria for when and how to transition between different parameter sets. By formalizing the parameter change process with defined transition conditions and layer specifications, the system reduces management complexity while enabling efficient multi-parameter printing.
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 enables efficient and accurate printing with reduced time and cost, maintaining safety and design specifications by applying necessary material properties only where required, while ensuring consistent material quality throughout the part.
Implementation Method 1
direct metal laser melting (DMLM) process, print a part using a same laser power, same laser speed, and same laser focus size
Data Source
AI summary
A method, medium, and system to obtain an assignment of one of a plurality of different additive manufacturing (AM) print parameter sets to each of a plurality of 3D volume elements forming a representation of the model of the part; define a plurality of groupings based on margin parameter values associated with the model of the part; assign a print parameter set to each grouping; automatically assign each of the plurality of print parameter sets to a laser of a multi-laser AM device; save a record of the determined print parameter sets to laser assignments; and transmit the record of the determined print parameter sets to laser assignments to an AM controller to control the multi-laser AM device to generate the part based on the model of the part and the determined print parameter sets to laser assignments, the generated part to be built in a single build.