Multi-Laser 3D Printing Through Parallel Model Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing methods, such as direct metal laser melting (DMLM), become inefficient for large or complex objects due to the sequential processing of 3D layers, leading to prolonged manufacturing times.
Innovation Solution
Dividing a master 3D model file into subordinate files, each representing a portion of the object, which are then processed in parallel using multiple lasers, allowing for simultaneous fabrication of object portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential processing of 3D layers is used in conventional additive manufacturing, then manufacturing precision is maintained, but manufacturing time becomes excessively long for large or complex objects
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 allows multiple lasers to process different portions simultaneously in parallel, dramatically reducing manufacturing time while maintaining precision through controlled processing of each segment
Solution Approach 2:
The patent transitions from single-thread sequential processing to multi-thread parallel processing by introducing multiple lasers operating simultaneously on different portions of the object. This dimensional change in processing architecture enables time reduction while preserving quality standards
2Productivity
If multiple lasers are used to process subordinate files in parallel, then manufacturing speed increases significantly, but system complexity increases
Solution Approach 1:
By segmenting the 3D model into subordinate files and assigning each to a dedicated laser, the system achieves parallel processing without requiring complex coordination between lasers. Each laser operates independently on its assigned segment, simplifying control architecture while maintaining high productivity
Solution Approach 2:
Each subordinate file is self-contained with complete processing instructions for its portion, allowing each laser to autonomously process its segment without continuous central coordination. This self-service approach reduces control system complexity while enabling parallel operation
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 reducing overall production 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.
Implementation Method 2
The at least two lasers emit different wavelengths of light. In some aspects, the at least two lasers emit different powers.
Data Source
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.