Multiple-Beam AM Exposure Strategy for Boundary Homogeneity
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Solution Overview
Problem
In layer-wise additive manufacturing, using multiple laser beams can reduce manufacturing time but leads to quality losses due to inhomogeneities at boundary regions between operating zones, resulting in deteriorated mechanical properties and reduced homogeneity of the manufactured objects.
Innovation Solution
A computer-based method generates a control dataset for additive manufacturing by optimizing the number of beams used for solidification based on quality and manufacturing time specifications, automatically adjusting the number of beams for each portion of the object cross-section to minimize boundary regions and ensure high homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beams are used for solidification, then manufacturing time is reduced, but inhomogeneities occur at boundary regions leading to deteriorated mechanical properties
Solution Approach 1:
The patent applies local quality by differentiating the treatment of boundary regions from interior regions. Specifically, it reduces the number of laser beams used in boundary regions (where inhomogeneities occur) while maintaining multiple beams in interior regions (where productivity gains are achieved). This localized adjustment of beam quantity resolves the contradiction by preserving mechanical property homogeneity at boundaries while maintaining high productivity in the bulk material.
Solution Approach 2:
The patent segments the construction field into distinct interior regions and boundary regions. This segmentation allows for differentiated beam allocation strategies: multiple beams for interior regions to maximize productivity, and reduced beam usage for boundary regions to maintain quality. The segmentation approach enables simultaneous optimization of both manufacturing time and mechanical property homogeneity.
2Productivity
If multiple laser beams are used for solidification, then manufacturing time is reduced, but quality losses occur due to inhomogeneities at boundary regions
Solution Approach 1:
The patent implements local quality by applying different beam configurations to different spatial zones. Interior regions receive multiple laser beams for rapid solidification (high productivity), while boundary regions receive reduced beam usage to prevent inhomogeneities (high reliability). This localized differentiation resolves the contradiction between productivity and quality by ensuring each region receives the appropriate level of processing.
Solution Approach 2:
The patent converts the harmful effect of boundary regions (where inhomogeneities occur) into a benefit by proactively reducing beam usage in these specific zones. This preventive measure transforms potential quality defects into controlled processing conditions, allowing the system to maintain high overall productivity while ensuring boundary regions achieve acceptable quality standards.
3Loss of time
If the number of beams is increased for faster solidification, then manufacturing time decreases, but inhomogeneities and quality losses increase
Solution Approach 1:
The patent applies local quality by spatially varying the number of laser beams based on position within the construction field. Interior positions receive multiple beams for rapid solidification (minimizing time loss), while boundary positions receive fewer beams to maintain solidification homogeneity. This localized beam allocation resolves the contradiction by optimizing solidification speed where it matters most while preserving quality at critical boundary zones.
Solution Approach 2:
The patent segments the construction field into interior and boundary regions with different solidification requirements. This segmentation enables differentiated beam usage: high beam density in interior regions for speed, low beam density at boundaries for homogeneity. The segmentation strategy allows the system to minimize overall manufacturing time while preventing inhomogeneities in critical regions.
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 allows for high-quality, homogeneous object production by optimizing beam usage, reducing inhomogeneities and achieving faster manufacturing times while maintaining mechanical property consistency across the object.
Implementation Method 1
controlled directing of radiation of at least one radiation source onto areas of a layer of building material that correspond to an object cross-section
Implementation Method 2
each beam where it impinges on the layer acting on the building material, in particular such that the same is solidified
Data Source
AI summary
The invention relates to a computer-assisted method for generating a control data set for an additive layer manufacturing device. In a first step, a layer data set is accessed, wherein points are marked in the data model which correspond to an object cross-section and at which the bid-up material should be solidified. In a second step, the layer data set is modified in such a way that for at least a portion of the object cross-section, the number of beams required for solidifying the build-up material inside said portion is determined preferably automatically, according to quality specifications of the portion and/or a manufacturing time of the object. In a third step, the modified layer data set is provided as a control data set for the additive layer manufacturing device.