Multi-Laser Scan Sequencing Against Fume Interference in SLM
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Solution Overview
Problem
In metal additive manufacturing using Selective Laser Melting (SLM) with multiple lasers, fumes and residues from upwind lasers interfere with downwind lasers, leading to reduced laser utilization and forming efficiency due to the need for sequential operation to avoid quality issues.
Innovation Solution
Divide forming areas into logical sub-regions along the blowing direction, plan a counter-wind scanning order, and control lasers to sequentially scan these sub-regions to ensure simultaneous operation without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lasers operate simultaneously in SLM equipment, then laser utilization and forming efficiency are improved, but fumes from upwind lasers interfere with downwind lasers affecting forming quality
Solution Approach 1:
The forming area is divided into multiple independent scanning regions, each assigned to a specific laser. This segmentation allows each laser to operate independently within its designated region without interfering with other lasers, enabling simultaneous operation while maintaining forming quality. The spatial division eliminates the upwind-downwind interference problem by creating isolated working zones.
Solution Approach 2:
The patent introduces a spatial dimension solution by arranging lasers and their corresponding scanning regions in a specific spatial configuration. By assigning each laser a dedicated forming region and controlling scanning paths to stay within assigned boundaries, the system transforms the interference problem into a spatial management issue that can be resolved through proper region allocation and boundary enforcement.
2Manufacturing precision
If only one laser operates at a time to avoid fume interference, then forming quality is maintained, but laser utilization and forming efficiency are reduced
Solution Approach 1:
The forming area is divided into multiple independent scanning regions, each assigned to a specific laser. This segmentation allows each laser to operate independently within its designated region without interfering with other lasers, enabling simultaneous operation while maintaining forming quality. The spatial division eliminates the upwind-downwind interference problem by creating isolated working zones.
Solution Approach 2:
Multiple lasers can operate simultaneously and continuously within their respective assigned regions, eliminating the idle time and sequential operation required when using a single laser. This continuous parallel operation maximizes laser utilization and maintains high forming quality throughout the entire forming area.
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
Ensures high-quality part formation by avoiding interference while improving laser utilization and forming efficiency in multi-laser SLM processes.
Implementation Method 1
an optical path system scans the cross-sectional profile of this powder layer to sinter it
Implementation Method 2
Metal additive manufacturing technology achieves the part forming by adding material
Implementation Method 3
an airflow system is configured to blow away the fumes and residues generated by laser sintering
Data Source
AI summary
A multi-laser scanning control method includes: dividing, along a blowing direction, each forming area corresponding to one of a plurality of lasers into a plurality of logical sub-regions; planning a scanning order for the plurality of logical sub-regions within each forming area according to a predetermined scanning order determination rule; and controlling each laser to sequentially scan the plurality of logical sub-regions within its corresponding forming area according to the scanning order until scanning of the forming areas corresponding to the plurality of lasers is completed.