Irradiation Optical Build Control for Uniform 3D Object Formation
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Solution Overview
Problem
Existing build systems face challenges in forming consistent build objects due to variations in the build process conditions across different areas of the target object, particularly when the energy beam's irradiation area is set multiple times at one area versus fewer times at another, leading to inconsistencies in the build object's height and size.
Innovation Solution
A build system that differentiates conditions by changing the relative position of the energy beam with respect to the target object, controlling the supply of build materials, and adjusting the energy beam's intensity and movement trajectory to ensure consistent build process conditions across varying areas, using a computer program to execute these processes and control the build apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the energy beam's irradiation area is set multiple times at one area, then the build process can cover the entire target object, but the build object's height and size become inconsistent across different areas
Solution Approach 1:
The patent applies local quality by differentiating build process conditions based on the number of times the irradiation area is set at each location. Areas irradiated multiple times receive adjusted build parameters (such as reduced build material supply rate or modified energy beam intensity) compared to areas irradiated fewer times, ensuring uniform build object characteristics across the entire target object despite varying irradiation frequencies.
2Manufacturing precision
If the build process conditions are differentiated across different areas, then consistency can be improved, but the control system complexity increases
Solution Approach 1:
The patent implements feedback by having the control system monitor the number of times the irradiation area is set at each location during the build process. Based on this feedback information, the control system automatically adjusts build process conditions for subsequent irradiation cycles, enabling dynamic adaptation without requiring complex manual intervention or pre-programming for each area.
3Productivity
If the energy beam moves faster to increase productivity, then the build process time is reduced, but the heat transfer to build materials becomes insufficient
Solution Approach 1:
The patent applies dynamics by making the energy beam's movement speed variable rather than constant. The control system dynamically adjusts the beam speed based on real-time conditions such as the number of previous irradiations at the current location and the required heat transfer amount, allowing optimization of both productivity and energy utilization throughout the build 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 reduces variations in the height and size of the build object by synchronizing the supply rate and heat transfer of build materials with the energy beam's movement, resulting in improved formation accuracy and consistency of three-dimensional structural objects.
Implementation Method 1
forming a build object by melting a powdery material with an energy beam and then solidifying the melted material again
Implementation Method 2
a size of a depth of focus of the optical system is larger than or equal to a thickness of one layer of the layered structural object and is smaller than a thickness of two layers of the layered structural objects
Data Source
AI summary
A build system is provided with: a build apparatus that performs a build process for forming a build object by supplying build materials to an irradiation area of an energy beam from a supply system while irradiating a target object with the energy beam from an irradiation system; and a change apparatus that is configured to change a relative position between the energy beam and the target object, wherein the build system differentiates a condition of the build process that is performed at a first area of the target object and a condition of the build process that is performed at a second area of the target object.