Multi-Laser Scan Sequencing for Fume-Aware SLM Forming
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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 part 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 part forming efficiency is improved, but fumes from upwind lasers interfere with downwind lasers reducing forming quality
Solution Approach 1:
The forming area is divided into multiple independent scanning sub-regions along the blowing direction, with each sub-region assigned to a specific laser. This segmentation allows lasers to operate simultaneously in different spatial zones without fume interference, as downwind lasers scan regions upstream of upwind laser fume paths.
2Manufacturing precision
If only one laser operates at a time to avoid fume interference, then forming quality is maintained, but laser utilization decreases
Solution Approach 1:
The patent implements dynamic scanning path planning where lasers are activated and deactivated based on real-time positioning and fume flow conditions. Multiple lasers can operate simultaneously when their scanning paths are spatially separated along the blowing direction, maximizing laser utilization while maintaining quality through adaptive control.
3Manufacturing precision
If lasers operate in sequence to prevent fume interference, then forming quality is ensured, but waiting time increases reducing efficiency
Solution Approach 1:
The system pre-calculates and plans scanning paths for multiple lasers considering the blowing direction and fume flow patterns before actual scanning begins. This preliminary action enables simultaneous operation of multiple lasers in optimized sequences, eliminating waiting times while ensuring downwind lasers never operate in the path of upwind laser fumes.
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 by reducing waiting times.
Implementation Method 1
an airflow system is configured to blow away the fumes and residues generated by laser sintering
Implementation Method 2
an optical path system scans the cross-sectional profile of this powder layer to sinter it, and bonding it with the previously formed portion or the substrate
Implementation Method 3
an optical path system scans the cross-sectional profile of this powder layer to sinter it
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
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.