Offset Optical Unit Layout for Multi-Beam 3D Workpiece Production
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Solution Overview
Problem
Existing three-dimensional workpiece production methods using beam melting processes are limited by long build times due to the use of a single beam source, and optical units are cumbersome and difficult to replace or maintain, especially when multiple units are required for increased productivity and space efficiency.
Innovation Solution
An optical unit with a compact geometry and rollers for easy placement and maintenance, featuring a housing with offset sections and rollers for lateral movement, allowing for efficient side-by-side arrangement and easy integration into an apparatus for beam melting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple optical units are provided to increase productivity, then build time is reduced, but device complexity and space requirements increase
Solution Approach 1:
The patent divides the optical system into multiple independent optical units, each capable of directing a laser beam to different locations on the raw material. This segmentation allows parallel processing of different workpiece regions, reducing overall build time while maintaining manageable complexity through modular design
Solution Approach 2:
The patent combines multiple optical units within a single apparatus, integrating them to work simultaneously on different portions of the workpiece. This merging of multiple beam sources enables parallel build operations, improving productivity without requiring separate standalone systems
2Productivity
If multiple optical units are arranged side by side to increase productivity, then build time is reduced, but space efficiency deteriorates
Solution Approach 1:
The patent arranges optical units in a stacked configuration along the vertical dimension rather than spreading them out horizontally. This dimensional reorganization allows multiple optical units to occupy overlapping horizontal footprints, improving space efficiency while maintaining the parallel processing capability for high productivity
3Area of stationary object
If optical units are made compact to improve space efficiency, then space utilization improves, but ease of maintenance and replacement deteriorates
Solution Approach 1:
The patent designs optical units as self-contained modular modules with standardized interfaces. Each optical unit can be independently removed and replaced without affecting other units, facilitating easy maintenance and replacement despite compact arrangement through vertical stacking and standardized mounting mechanisms
4Device complexity
If a single beam source is used to simplify the system, then device complexity is reduced, but productivity deteriorates due to long build times
Solution Approach 1:
The patent segments the single beam source into multiple independent beam sources, each capable of operating autonomously on different workpiece regions. This segmentation enables parallel processing, dramatically reducing build time while the modular design keeps system complexity manageable through standardized optical units
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 configuration enhances productivity by enabling multiple beams to be directed simultaneously, reduces the complexity of optical unit placement and maintenance, and allows for a more compact and efficient use of space within the apparatus.
Implementation Method 1
The laser radiation penetrates the raw material powder material and solidifies it, for example as a result of heating, which causes melting or sintering
Implementation Method 2
an opening provided in the housing bottom which is transparent to the beam so that the beam can pass through the opening
Data Source
AI summary
The invention relates to an optical unit for use in an apparatus for producing a three-dimensional workpiece by a beam melting process. The optical unit comprises a beam optics for generating a beam and directing the beam to a predetermined location, and a housing having a housing bottom and an opening provided in the housing bottom which is transparent to the beam so that the beam can pass through the opening. The optical unit has a lower section comprising the housing bottom and having two side walls each extending parallel to a first direction, and an upper section connected to the lower section and having two side walls each extending parallel to the first direction, the lower section and the upper section being arranged offset from each other such that a first side wall of the side walls of the lower section does not extend in the same plane as a first side wall of the side walls of the upper section and a second side wall of the side walls of the lower section does not extend in the same plane as a second side wall of the side walls of the upper section. Furthermore, the invention relates to an apparatus for producing a three-dimensional workpiece.