Multi-Unit Irradiation Layout for Faster 3D Layer Production
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Solution Overview
Problem
Additive layer manufacturing methods for producing three-dimensional workpieces are inefficient due to the need for complex optics and deflection devices to guide laser beams over the entire workpiece surface, increasing processing time and reducing efficiency.
Innovation Solution
A device with a plurality of irradiation units that selectively irradiate individual regions of the build surface, eliminating the need for scanner units by dividing the surface into smaller, matrix-like zones, allowing for simultaneous or sequential activation of units to cover the surface efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single laser beam is guided over the entire workpiece surface using scanner units, then the workpiece can be irradiated selectively, but the processing time increases and manufacturing efficiency decreases
Solution Approach 1:
The patent divides the workpiece surface into multiple smaller regions, with each irradiation unit responsible for a specific region. This segmentation allows parallel processing of different areas simultaneously, eliminating the need for a single beam to traverse the entire surface and significantly reducing processing time while maintaining selective irradiation precision.
Solution Approach 2:
The patent transitions from a single-point sequential irradiation approach to a multi-point parallel irradiation approach by arranging multiple irradiation units in a matrix configuration. This dimensional expansion from one to many irradiation sources enables simultaneous processing across the workpiece surface.
2Adaptability or versatility
If complex optics and deflection devices are used to guide the laser beam, then flexible irradiation control is achieved, but the device complexity increases
Solution Approach 1:
Instead of using complex optics and deflection devices to guide a single beam, the patent segments the irradiation function into multiple independent irradiation units. Each unit directly irradiates its assigned region without requiring complex beam steering mechanisms, thereby reducing device complexity while maintaining irradiation control flexibility through independent unit activation.
Solution Approach 2:
The patent replaces the mechanical beam deflection system (scanner units with moving mirrors) with a static array of multiple irradiation units. This substitution eliminates the need for mechanical movement and complex optical paths, simplifying the overall device structure while achieving comparable or superior control flexibility.
3Manufacturing precision
If the laser beam travels over the entire workpiece layer, then complete coverage is achieved, but the manufacturing time increases
Solution Approach 1:
The patent segments the workpiece surface into multiple regions that can be processed in parallel by corresponding irradiation units. This allows complete coverage of the workpiece layer to be achieved simultaneously across all regions rather than sequentially, dramatically reducing the time required while ensuring thorough coverage of the entire surface.
Solution Approach 2:
The patent combines multiple irradiation units to work simultaneously on different portions of the workpiece layer. By merging their processing capabilities, the system achieves complete coverage of the entire surface in the time it would take a single unit to cover one region, effectively parallelizing the coverage process.
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 production time by allowing multiple regions to be irradiated simultaneously or in quick succession, improving manufacturing efficiency and reducing internal stresses through controlled, localized solidification.
Implementation Method 1
irradiation by means of electromagnetic radiation, for example in the form of laser radiation
Implementation Method 2
irradiation by means of electromagnetic radiation, for example in the form of laser radiation
Implementation Method 3
The laser radiation penetrates the molding compound and solidifies it, for example as a result of heating, which causes fusion or sintering
Implementation Method 4
solidifies it, for example as a result of heating, which causes fusion or sintering
Implementation Method 5
solidifies it, for example as a result of heating, which causes fusion or sintering
Data Source
AI summary
The application relates to a device for producing three-dimensional workpieces, the device including: a structural surface designed to receive a molding compound; and an irradiation arrangement designed to selectively irradiate the molding compound on the structural surface with electromagnetic radiation, in order to produce a workpiece by means of generative layer construction, where the irradiation device comprises a plurality of irradiation units, the irradiation units being designed to irradiate an individual region of the structural surface respectively associated with the irradiation units, and where the beams emitted by the irradiation units respectively have a cross-sectional surface corresponding to between approx. 2% and approx. 170% of the surface of the respectively associated individual region. The application also relates to the use of such a device and to a method for producing three-dimensional workpieces by means of such a device.