Powder Bed Energy Patterning With Beam Reuse for High-Resolution Throughput
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Solution Overview
Problem
Current powder bed fusion additive manufacturing machines face limitations in part size, manufacturing cost, resolution of part details, and throughput due to the high cost and complexity of scaling up laser power, which increases the cost and can degrade printable resolution.
Innovation Solution
The system employs energy patterning and beam reuse techniques, using multiple energy sources and beam shaping optics to efficiently direct and recycle energy, allowing for two-dimensional energy patterning and improved energy distribution, which enhances manufacturing efficiency and reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser power is increased to increase material throughput rate, then productivity is improved, but manufacturing cost increases proportionally
Solution Approach 1:
The patent divides the single high-power laser beam into multiple lower-power beams using beam splitting optics. This segmentation allows the system to achieve high material throughput rate by processing multiple areas simultaneously while avoiding the need for a single expensive high-power laser, thus resolving the contradiction between productivity and manufacturing cost.
Solution Approach 2:
The patent transitions from one-dimensional sequential processing to two-dimensional parallel processing by distributing the laser beam across multiple processing zones. This dimensional change enables simultaneous melting of powder in different areas, increasing material throughput rate without requiring proportional increase in laser power, thereby reducing manufacturing cost.
2Productivity
If laser power is increased to increase material throughput rate, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent segments the laser beam into multiple beams using optical splitting elements, which are relatively simple components compared to the complexity of managing multiple independent high-power lasers. This segmentation approach increases material throughput rate while adding minimal system complexity.
Solution Approach 2:
The patent employs a single laser source that serves multiple processing functions simultaneously by directing split beams to different areas of the powder bed. This multi-functionality approach increases productivity while avoiding the complexity of multiple separate laser systems.
3Productivity
If laser spot size is increased to maintain optimum power flux at higher power, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent divides the high-power laser beam into multiple lower-power beams, each maintaining a small spot size for high resolution. This segmentation allows the system to process larger areas (improving productivity) while each individual beam maintains the small spot size needed for manufacturing precision.
Solution Approach 2:
The patent transitions from increasing spot size in one dimension to distributing multiple small spot beams across two-dimensional space. This approach maintains manufacturing precision by keeping individual spot sizes small while improving productivity through parallel processing across multiple locations.
4Manufacturing precision
If single laser beam is divided into multiple beams to maintain resolution, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent uses optical beam splitting components to divide a single laser beam into multiple beams. These segmentation components are simpler than alternative approaches such as using multiple independent lasers or complex scanning mechanisms, thus improving manufacturing precision while adding minimal system complexity.
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 enables the production of larger parts with improved resolution and reduced manufacturing costs by optimizing energy use and distribution, thereby increasing throughput and reducing the economic burden of scaling up the machines.
Implementation Method 1
to melt a given volume of material the laser must deliver both enough energy to bring it up to the melting temperature, and the phase change energy required to melt
Implementation Method 2
the phase change energy required to melt
Implementation Method 3
uses one or more focused energy sources, such as a laser or electron beam
Implementation Method 4
focused energy sources
Implementation Method 5
By selectively activating pixels, the system melts the powder only in the desired locations
Data Source
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AI summary
An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.