Multi-Laser Powder Bed Stitching to Prevent Surface Defects
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Solution Overview
Problem
Multi-laser additive manufacturing systems face misalignment issues, leading to surface defects such as voids and cracks in printed parts due to inconsistent melting and bonding of metal powder.
Innovation Solution
The system constrains laser stitching regions to locations where misalignment is tangent to the component's surface, using a computing system to determine misalignment vectors and identify optimal stitching positions, thereby minimizing or eliminating surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lasers are used to manufacture components simultaneously, then manufacturing time and production cost are reduced, but laser misalignment occurs leading to surface defects
Solution Approach 1:
The system performs preliminary determination of misalignment vectors and identification of optimal stitching positions before actual laser manufacturing. By pre-calculating the misalignment characteristics and planning the stitching regions in advance, the system prepares compensation strategies that prevent surface defects from occurring during the manufacturing process
Solution Approach 2:
The system dynamically adjusts laser beam parameters including position, angle, and intensity based on the determined misalignment vectors. By changing these parameters in real-time according to the calculated misalignment characteristics, the system compensates for laser misalignment and maintains consistent melting and bonding quality across stitching regions
2Productivity
If laser beams are closely positioned to maximize build plate utilization, then manufacturing efficiency increases, but misalignment between lasers causes inconsistent melting and bonding
Solution Approach 1:
The system implements a feedback mechanism where misalignment vectors are determined based on actual laser positions and characteristics, and this information feeds back into the stitching region generation process. The system continuously monitors and adjusts laser parameters based on measured misalignment, ensuring consistent melting and bonding quality even when lasers are closely positioned
Solution Approach 2:
The system applies different laser parameters and stitching strategies to different regions of the build plate based on local misalignment characteristics. By generating stitching regions specific to each area where misalignment occurs, the system maintains reliable melting and bonding quality locally while maximizing overall build plate utilization
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 effectively reduces or eliminates surface defects by aligning laser stitching regions with the component's surface, enhancing the quality and consistency of additively manufactured parts.
Implementation Method 1
The laser devices each generate a laser beam that melts the powder material on the build plate in and around the area where the laser beam is incident on the powder material, resulting in a melt pool.
Data Source
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AI summary
The method for manufacturing a solid component includes determining a misalignment vector (250) field having a plurality of misalignment vectors (250). The method further includes identifying potential stitching positions (150) where the solid component (100) is generally tangent to one or more misalignment vectors (250) in the misalignment vector (250) field. The method further includes generating a plurality of first hatching paths (110), a plurality of second hatching paths (112), and one or more stitching regions (114). The method further includes selectively directing the first laser beam (16) across a powder bed (23) along the plurality of first hatching paths (110) to consolidate a first portion (102) of the solid component (100). The method further includes selectively directing the second laser beam (17) across the powder bed (23) along the plurality of second hatching paths (112) to consolidate a second portion (104) of the solid component (100).