Non-linear Laser Traverse for 3D Printing Speed and Precision
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Solution Overview
Problem
Conventional rapid prototyping methods using selective laser sintering face limitations in reducing the time required for the energy beam to traverse the area requiring hardening without compromising the quality or mechanical properties of the produced three-dimensional objects.
Innovation Solution
The process involves applying a layer of powder material and focusing a beam of electromagnetic radiation to traverse in a non-linear path, which can include periodic oscillation or superposition of translational and rotary motion, allowing for efficient melting and sintering of the material while maintaining precision and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the traverse speed of the energy beam is increased to reduce processing time, then productivity is improved, but manufacturing precision deteriorates due to acceleration and retardation effects causing uneven areas at edges
Solution Approach 1:
The patent applies dynamics by making the energy beam traverse path non-linear with varying speed. The beam moves faster in the center regions and slower at the edges, creating a speed profile that compensates for acceleration and retardation effects. This dynamic speed variation allows higher overall traverse speeds while maintaining uniform melting and surface quality across the entire irradiation area.
Solution Approach 2:
The patent changes the traverse speed parameter as a function of position across the irradiation area. By adjusting the speed parameter dynamically based on location (faster at edges, slower at center), the process achieves both high productivity and manufacturing precision. The non-linear path and variable speed parameters resolve the contradiction between fast processing and uniform quality.
2Productivity
If the distance between radiation lines is increased to reduce traverse time, then productivity is improved, but manufacturing precision deteriorates due to inadequate bonding between individual irradiation lines
Solution Approach 1:
The patent optimizes the distance parameter between radiation lines by using non-linear traversal paths. The varying speed and curved paths ensure adequate overlap and bonding between lines even when the nominal distance is increased, maintaining manufacturing precision while improving productivity through more efficient beam utilization.
Solution Approach 2:
The patent employs curved or non-linear traversal paths instead of straight lines. This curvature allows the energy beam to cover areas more efficiently and ensures better bonding between adjacent irradiation lines by creating overlapping zones, thereby maintaining bonding quality while reducing overall traverse time.
3Productivity
If the traverse speed is increased to reduce processing time, then productivity is improved, but manufacturing precision deteriorates due to insufficient melting and resolidification time
Solution Approach 1:
The patent uses dynamic speed variation during beam traversal, slowing down at critical regions (edges and corners) where adequate melting and resolidification time is essential for quality, while maintaining higher speeds in less critical central regions. This dynamic adjustment ensures proper melting quality throughout while maximizing overall productivity.
Solution Approach 2:
The patent implements periodic variations in beam traverse speed, creating a rhythm of acceleration and deceleration that corresponds to the geometric features being processed. This periodic speed modulation ensures sufficient energy delivery and proper melting/resolidification cycles at all locations, maintaining manufacturing precision at higher average speeds.
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 enables a reduction in the time required for the energy beam to traverse the area without compromising the quality or mechanical properties of the objects, allowing for faster production of three-dimensional objects with improved surface finish and mechanical properties.
Implementation Method 1
plastics powders are selectively briefly irradiated by a laser beam in a chamber, and the powder particles impacted by the laser beam therefore melt
Implementation Method 2
focusing a beam of electromagnetic radiation through a lens on a plane of the material layer; selectively melting the material under the focus of the beam
Implementation Method 3
focusing a beam of electromagnetic radiation through a lens on a plane of the material layer
Implementation Method 4
The molten particles coalesce and rapidly resolidify to give a solid mass
Data Source
AI summary
A process for melting/sintering powder particles for layer-by-layer production of three-dimensional objects wherein a layer of powder particles is irradiated by a nonlinear path of an electromagnetic radiation is provided. Also provided are an apparatus to conduct the process and three dimensional objects obtained by the process.