Non-Circular Beam Alignment for Powder Bed Irradiation Planning
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Solution Overview
Problem
Conventional planning devices and methods for locally selective irradiation in additive manufacturing with powder materials are not configured to handle non-circular beam shapes, which can limit construction rate, stability, and component quality.
Innovation Solution
A planning device that determines vector alignments and specifies beam alignments for non-circular energy beam shapes relative to irradiation vectors, allowing for increased construction rate, improved component quality, and reduced warpage and cracks by optimizing beam shape and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a non-circular beam shape is used for the energy beam, then the construction rate is increased, but the beam alignment becomes complex and requires specific orientation relative to the displacement direction
Solution Approach 1:
The planning device calculates and determines the beam alignment in advance before the actual irradiation process. By pre-determining the orientation of non-circular beam shapes relative to irradiation vectors and displacement directions, the system prepares alignment data that guides the beam shaping and steering mechanisms, thereby enabling complex beam orientations without adding operational complexity during manufacturing
Solution Approach 2:
The planning device serves multiple functions: it calculates irradiation vectors, determines vector alignments, specifies beam alignments for non-circular shapes, and coordinates with beam shaping and steering mechanisms. This multi-functional approach consolidates what would otherwise require separate systems, managing complexity through integration rather than proliferation of components
2Manufacturing precision
If conventional planning devices are used, then the device complexity is low, but the manufacturing precision and component quality are limited
Solution Approach 1:
The planning process is segmented into distinct computational steps: obtaining irradiation vectors, determining vector alignments in the coordinate system, and specifying beam alignments for non-circular shapes. This segmentation allows each function to be handled by dedicated software modules, managing computational complexity through structured decomposition while achieving high manufacturing precision
Solution Approach 2:
The patent replaces physical mechanical alignment systems with computational methods. Instead of using complex mechanical devices to physically align non-circular beams, the system uses software-based planning that calculates and specifies beam alignments digitally, then translates these specifications to control optical or electromagnetic beam shaping mechanisms, thereby reducing mechanical complexity while improving precision
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
The solution enables the use of non-circular beam shapes, enhancing construction efficiency and component quality by aligning beam shapes with vector alignments, resulting in improved surface quality and reduced defects.
Implementation Method 1
an energy beam is typically displaced selectively to predetermined irradiation positions of a work region in order to locally solidify powder material arranged in the work region
Data Source
AI summary
A planning device for planning locally selective irradiation of a work region using an energy beam in order to produce a component from a powder material arranged in the work region is provided. The planning device is configured to obtain a plurality of irradiation vectors for irradiating a powder material layer arranged in the work region with the energy beam. The planning device is further configured to determine a vector alignment in a coordinate system on the work region for at least one irradiation vector of the plurality of irradiation vectors, and to specify, for the at least one irradiation vector, a beam alignment for a non-circular beam shape of the energy beam on the work region relative to the vector alignment of the at least one irradiation vector.