Multi-Scanner SLS Exposure Control for Balanced Build Time
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Solution Overview
Problem
Existing multi-scanner laser sintering or melting systems face inefficiencies in construction time due to varying irradiation times and areas among scanners, leading to suboptimal exposure distribution across the construction area.
Innovation Solution
The method involves recording and comparing irradiation times and areas for each scanner, dynamically adjusting scan field boundaries to equalize exposure times and areas, allowing for iterative optimization and incremental adjustments to minimize construction time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple scanners are used to expose different sections of the construction field, then the construction area coverage is improved, but the construction time becomes unbalanced due to varying irradiation times and areas among scanners
Solution Approach 1:
The patent implements dynamic adjustment of scan field boundaries between multiple scanners during the construction process. The control system continuously monitors irradiation times and areas for each scanner, then dynamically redistributes the construction field sections to equalize the exposure workload. This dynamic reassignment ensures that all scanners operate at optimal utilization levels, preventing any single scanner from becoming a bottleneck and thereby minimizing total construction time while maintaining full construction field coverage.
2Ease of operation
If scan field boundaries are fixed for each scanner, then the system operation is simplified, but streaking artifacts appear on the surface due to inconsistent exposure distribution
Solution Approach 1:
The patent employs a feedback mechanism where the control system continuously monitors the irradiation parameters (time and area) for each scanner during the construction process. Based on this feedback, the system automatically adjusts the scan field boundaries to optimize exposure distribution across all scanners. This closed-loop control equalizes the workload among scanners, preventing the formation of streaking artifacts caused by inconsistent exposure, while the adjustments are made transparently without requiring complex manual intervention, thus maintaining ease of operation.
3Device complexity
If the irradiation workload is unevenly distributed among scanners, then the system setup is simpler, but the overall productivity is reduced due to idle scanner time
Solution Approach 1:
The patent implements dynamic load balancing that automatically optimizes the distribution of irradiation workload among multiple scanners during construction. The control system monitors the actual irradiation time and area for each scanner in real-time, then dynamically reassigns construction field sections to equalize the exposure workload. This ensures all scanners remain actively utilized throughout the construction process, eliminating idle time and maximizing overall system productivity, while the automatic nature of the optimization keeps the system configuration relatively simple.
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 reduces construction time by ensuring balanced scanner usage and preventing streaking, maintaining optimal exposure distribution throughout the process.
Implementation Method 1
selective laser sintering or laser melting device for producing three-dimensional objects
Implementation Method 2
laser sintering or laser melting device for producing three-dimensional objects by selectively irradiating a construction material
Implementation Method 3
laser sintering or laser melting device for producing three-dimensional objects by selectively irradiating a construction material
Data Source
Figure 1
Figure 2a~2c
AI summary
The invention relates to a method for controlling the exposure of a selective laser sintering or laser melting device for producing three-dimensional objects, with the following method steps: providing a selective laser sintering or laser melting device (1), in which three-dimensional objects can be produced by successively consolidating layers of a powder-like building material (6) that can be consolidated by means of radiation at the locations corresponding to the respective cross section of the object, wherein the device provided comprises an irradiating unit for irradiating layers of the building material that has a plurality of separately activatable scanners irradiating the building material simultaneously, comprising separately recording the irradiating times of each individual scanner (8a, 8b) and/or the irradiating areas covered by each individual scanner in a first step and storing the recorded irradiating times and/or irradiating areas; comparing the irradiating times and/or irradiating areas of the individual scanners with one another; re-determining the surface regions of a powder layer to be irradiated by each individual scanner in such a way that the irradiating times for each individual scanner are approximated to one another as much as possible and/or the irradiating areas of each individual scanner are made to match one another as far as possible in terms of their surface area.