Oscillating Energy Beam Paths for Additive Manufacturing Interlace Regions

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Solution Overview

Problem

Existing additive manufacturing systems using multiple energy beams face challenges in ensuring smooth and consistent transitions between build plane regions, leading to potential misalignment and deviations along the outer contour of the three-dimensional object.

Innovation Solution

The use of multiple energy beams with controlled power profiles and oscillating paths that overlap in an interlace region, allowing for synchronized irradiation to create a common melt pool and ensure consistent consolidation across the build area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple energy beams are used to consolidate multiple build plane regions in parallel, then productivity is improved, but manufacturing precision deteriorates due to misalignment and deviations along the outer contour

Engineering Contradiction:

Improveconsolidation rateVSAvoidalignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

An interlace region is introduced as an intermediary zone between build plane regions consolidated by different energy beams. This interlace region serves as a transition zone where beams from multiple energy sources overlap and interact, ensuring smooth transitions and eliminating misalignment issues at the boundaries between regions consolidated by different beams.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Multiple energy beams are merged in the interlace region where their paths overlap. The beams are coordinated to simultaneously irradiate the same build material in this region, creating a unified consolidation effect that ensures continuity and eliminates gaps or misalignments between regions processed by different beams.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If multiple energy beams are used to consolidate multiple build plane regions in parallel, then productivity is improved, but reliability deteriorates due to potential misalignment and deviations

Engineering Contradiction:

Improveconsolidation rateVSAvoidconsistency of transition

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The interlace region acts as a mediator that ensures reliable and consistent transitions between build plane regions. By designating a specific overlapping zone where multiple beams converge, the system guarantees that transitions between regions are smooth and predictable, eliminating the reliability issues associated with abrupt boundaries between parallel consolidation zones.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The interlace region is pre-planned and pre-coordinated in the process design. The overlapping paths of multiple energy beams are predetermined to ensure proper synchronization and power distribution before the actual consolidation process begins, preventing misalignment and ensuring consistent transitions.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If energy beams travel along straight paths, then device complexity is reduced, but manufacturing precision deteriorates due to inability to create smooth transitions between build plane regions

Engineering Contradiction:

Improvebeam path controlVSAvoidtransition smoothness

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The beam paths are transformed from static straight lines to dynamic oscillating trajectories. The energy beams oscillate within the interlace region, creating a wobbling motion that ensures complete and uniform consolidation of the transition zone. This dynamic path allows the beams to systematically cover the entire interlace region while maintaining coordination with other beams.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The energy beams perform periodic oscillations within the interlace region during the consolidation process. This periodic wobbling motion ensures that all areas within the interlace region receive adequate energy input and that transitions between build plane regions are smooth and uniform, eliminating the precision issues associated with simple straight-line paths.

Inventive Principle:

Principle #19Periodic action

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 enhances the accuracy and consistency of the additive manufacturing process, reducing the risk of misalignment and improving the uniformity of the three-dimensional object's properties and structural characteristics.

Implementation Method 1

one or more energy beams are directed onto a powder bed to consolidate melt, fuse, or sinter sequential layers of build material

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

additive manufacturing may involve a powder bed fusion process in which one or more energy beams are directed onto a powder bed

Methodology Applied

Scientific EffectPowder bed fusion:

Implementation Method 3

directing the first energy beam along a first oscillating path and directing the second energy beam along a second oscillating path overlapping with the first oscillating path

Methodology Applied

Scientific EffectElectromagnetic radiation heating:

Data Source

PatentUS12280538B2Additive manufacturing methods and systems with two beams traveling along opposing, wobbling paths

Publication Date: 2025.04.22 GENERAL ELECTRIC CO

AI summary

Methods of additively manufacturing a three-dimensional object include irradiating a first build plane region using a first energy beam, irradiating a second build plane region using a second energy beam, and irradiating an interlace region between the first build plane region and the second build plane region. Irradiating the interlace region comprises directing the first energy beam along a first oscillating path and directing the second energy beam along a second oscillating path intersecting and overlapping with the first oscillating path.