Parallel Irradiation Units for Selective 3D Workpiece Layering
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Solution Overview
Problem
Existing additive layer manufacturing methods require complex optics and deflection devices, such as scanner units, to achieve selective irradiation of molding compounds, leading to increased processing time and reduced efficiency.
Innovation Solution
A device comprising a build surface and an irradiation arrangement with multiple irradiation units, each unit capable of emitting a beam to selectively irradiate individual regions of the build surface, allowing for simultaneous or sequential activation of units to cover the entire surface efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex optics and deflection devices (scanner units) are used to achieve selective irradiation, then the molding compound can be irradiated selectively, but the processing time increases and efficiency decreases
Solution Approach 1:
The irradiation arrangement is divided into multiple independent irradiation units (e.g., 5-10 or more), each capable of independently irradiating a specific region of the molding compound. This segmentation allows parallel processing of multiple regions simultaneously, eliminating the need for sequential scanning and dramatically reducing processing time while maintaining selective irradiation capability.
Solution Approach 2:
The patent replaces the mechanical deflection system (scanner units with moving mirrors) with a static array of multiple fixed irradiation units. Instead of mechanically deflecting a single beam across the build surface, multiple beams are positioned simultaneously at different locations, substituting mechanical motion with a multi-source configuration that achieves the same selective irradiation goal without the time penalty of beam traversal.
2Device complexity
If a single irradiation source with beam deflection is used, then the device complexity is reduced, but the processing time increases due to sequential irradiation
Solution Approach 1:
The single irradiation source is segmented into multiple independent irradiation units distributed across the build surface. Each unit operates independently and simultaneously, converting a sequential single-source process into a parallel multi-source process. This eliminates the time loss associated with beam deflection and traversal while reducing device complexity by removing the scanner unit infrastructure.
Solution Approach 2:
The patent transitions from a one-dimensional beam traversal approach (single source moving across the surface) to a two-dimensional array of stationary sources. By distributing irradiation units across the build surface in multiple locations, the system irradiates multiple regions simultaneously in parallel, effectively adding a spatial dimension to the irradiation process and eliminating sequential time loss.
3Manufacturing precision
If laser beam oscillation along scan vectors is used to produce filled workpiece layers, then complete coverage is achieved, but the manufacturing time increases
Solution Approach 1:
The build surface is divided into multiple regions, each handled by a dedicated irradiation unit. Instead of oscillating a single beam to cover the entire surface, multiple beams simultaneously irradiate their respective regions, achieving complete workpiece layer coverage through parallel processing. This segmentation approach maintains manufacturing precision while dramatically improving productivity by eliminating sequential scan operations.
Solution Approach 2:
The patent enables continuous simultaneous irradiation of multiple regions across the build surface. Rather than the intermittent back-and-forth motion of oscillating beams, multiple irradiation units maintain continuous useful action on their respective target regions at the same time, eliminating idle traversal time and maximizing manufacturing efficiency while ensuring complete layer coverage.
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 significantly reduces production time and increases efficiency by allowing multiple regions to be irradiated simultaneously, eliminating the need for complex beam deflection systems.
Implementation Method 1
irradiation by means of electromagnetic radiation, for example in the form of laser radiation... The laser radiation penetrates the molding compound and solidifies it, for example as a result of heating, which causes fusion or sintering
Implementation Method 2
solidifies it, for example as a result of heating, which causes fusion or sintering
Implementation Method 3
solidifies it, for example as a result of heating, which causes fusion or sintering
Data Source
AI summary
The application relates to a device for producing three-dimensional workpieces, the device including: a structural surface designed to receive a molding compound; and an irradiation arrangement designed to selectively irradiate the molding compound on the structural surface with electromagnetic radiation, in order to produce a workpiece by means of generative layer construction, where the irradiation device comprises a plurality of irradiation units, the irradiation units being designed to irradiate an individual region of the structural surface respectively associated with the irradiation units, and where the beams emitted by the irradiation units respectively have a cross-sectional surface corresponding to between approx. 2% and approx. 170% of the surface of the respectively associated individual region. The application also relates to the use of such a device and to a method for producing three-dimensional workpieces by means of such a device.