3D Powder Bed Fusion Beam Scanning for Stronger Layer Bonding
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Solution Overview
Problem
Existing three-dimensional powder bed fusion additive manufacturing (PBF-AM) apparatuses face challenges in improving the quality of the built three-dimensional structures.
Innovation Solution
A three-dimensional PBF-AM apparatus and method that control the beam deflector to irradiate adjacent solidified points before and after irradiating the next point with a beam, creating activated points for improved bonding during the melting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sequential line-by-line beam scanning is performed with dummy scanning between lines, then the manufacturing process is simple and easy to control, but the bonding quality between adjacent layers deteriorates due to insufficient thermal activation
Solution Approach 1:
The patent applies preliminary action by irradiating the solidified point adjacent to the next irradiation point before performing the main irradiation. This pre-irradiation activates the adjacent solidified material, creating a thermally activated state that improves bonding when the new material is deposited. The controller executes this preliminary irradiation step before the main scanning process, ensuring optimal bonding conditions are established in advance.
2Productivity
If the beam irradiates only the next irradiation point without revisiting solidified points, then the manufacturing efficiency is high, but the structural integrity and bonding strength deteriorate
Solution Approach 1:
The patent implements continuity of useful action by integrating the irradiation of solidified points into the continuous beam scanning process. Instead of separate operations, the controller seamlessly combines main irradiation of new points with preliminary irradiation of adjacent solidified points, maintaining continuous beam utilization. This ensures both manufacturing efficiency and optimal bonding through sustained thermal activation without interrupting the scanning flow.
3Object-affected harmful factors
If dummy scanning is performed between lines to prevent material melting, then harmful overheating is avoided, but the activation of solidified points for improved bonding is insufficient
Solution Approach 1:
The patent applies local quality by differentiating the irradiation approach between different regions and timing. Instead of uniform dummy scanning across the entire build area, the controller selectively irradiates only the specific solidified points adjacent to the next irradiation points with controlled energy. This localized preliminary irradiation provides sufficient thermal activation for bonding while avoiding excessive heating that would occur with comprehensive dummy scanning of the entire line.
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
Enhances the quality of the three-dimensional structures by ensuring proper melting and bonding of material layers, resulting in improved structural integrity.
Implementation Method 1
The beam emitter emits a beam toward the powder layer spread on the stage... irradiates the powder material spread on a stage with a beam to melt and coagulate the powder material
Implementation Method 2
The beam deflector deflects the beam emitted from the beam emitter... The controller controls the beam deflector to irradiate at least one of the solidified points adjacent to the next irradiation point with the beam
Data Source
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AI summary
A beam emitter (2) of a three-dimensional powder bed fusion additive manufacturing apparatus (1) reflecting one aspect of the present invention irradiates a powder layer spread on a stage (6) with a beam. A beam deflector (10) deflects the beam emitted from the beam emitter (2). A controller (30) controls the beam deflector (10). A point to be irradiated with the beam next in the powder layer is defined as a next irradiation point, and points that have been irradiated with the beam and solidified are defined as solidified points. The controller (30) controls the beam deflector (10) to irradiate at least one of the solidified points adjacent to the next irradiation point with the beam and then irradiate the next irradiation point with the beam, or to irradiate the next irradiation point with the beam and then irradiate at least one of the solidified points adjacent to the next irradiation point with the beam before the next irradiation point is solidified.