Powder Bed AM Temperature Feedback for Dimensional Accuracy
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Solution Overview
Problem
Existing additive manufacturing technologies face challenges in producing large objects with varying sizes and geometries, leading to thermal-driven deviations and dimensional errors due to uncontrolled thermal states of the melt pool, resulting in inefficiencies and material waste.
Innovation Solution
An additive manufacturing apparatus with real-time temperature measurement and adjustment capabilities, using a temperature control mechanism to monitor and adjust the growing part's temperature, ensuring precise cooling and solidification to the desired size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time temperature measurement and adjustment capabilities are added to control thermal states, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback control system where a temperature sensor continuously monitors the melt pool temperature, and the controller adjusts irradiation beam parameters in real-time based on this feedback to maintain desired thermal conditions and minimize dimensional deviations
Solution Approach 2:
The patent replaces mechanical/physical intervention methods with automated control systems that use sensors and algorithms to monitor and adjust process parameters, substituting manual or mechanical temperature control with electronic feedback control
2Productivity
If parameters of irradiation beam are efficiently controlled to produce large objects with varying geometries, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent employs dynamic control of irradiation beam parameters during the additive manufacturing process, allowing real-time adjustment of intensity, speed, and duration based on the evolving thermal state and geometric requirements of different parts of the object
Solution Approach 2:
The patent systematically varies irradiation beam parameters (intensity, speed, duration) and platform temperature throughout the build process to optimize production efficiency for different geometries while managing thermal effects
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
Enables the production of large, complex objects with improved precision and reduced material waste, achieving time- and cost-efficient manufacturing with minimal dimensional errors.
Implementation Method 1
a temperature sensor or other mechanism that measures a real-time temperature of the growing part
Implementation Method 2
a focused energy beam is used to fuse powder particles together
Implementation Method 3
Selected portions 107 of the powder layer are irradiated in each layer using, for example, laser beam 108, thereby creating a melt pool
Implementation Method 4
the part may cool and solidify to the correct or desired size
Data Source
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AI summary
An apparatus for powder-based additive manufacturing of an object is provided. The apparatus includes a powder delivery mechanism, a powder recoating mechanism, an irradiation beam directing mechanism and a temperature control mechanism that at least measures a real-time temperature of at least one growing part of a built object. The apparatus includes a build unit, a positioning mechanism, and a rotating mechanism. The build unit attaches to the positioning mechanism providing the build unit with independent movements in at least two dimensions. The build unit also attaches to the rotating mechanism and rotates around and above a build platform during production. A method of manufacturing the object using the apparatus includes repetitive cycles of depositing powder onto a build platform, irradiating at least one selected portion of the powder to form at least one fused layer, and measuring a real-time temperature of at least one selected portion of the at least one fused layer.