Powder Bed Energy Patterning for Layer Cooling Control
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Solution Overview
Problem
Current additive manufacturing methods, such as 3D printing, face challenges in achieving smooth and efficient manufacturing of printed parts due to limitations in material removal and processing techniques, particularly in achieving desired structural properties and efficient energy use.
Innovation Solution
The implementation of a system and method that utilizes two-dimensional energy patterning for both printing and heat treatment, incorporating multiple energy sources like lasers and electron beams, with advanced beam shaping and patterning units, and energy recycling to optimize energy efficiency and control thermal processes during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional material removal methods (drilling, cutting, grinding) are used to form parts, then manufacturing flexibility is improved, but material waste and processing time increase
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from material removal to material addition through controlled energy input. By varying energy parameters (laser power, electron beam current, scanning speed) and material parameters (powder feed rate, layer thickness), the system achieves both flexibility and material efficiency inherent to additive manufacturing
Solution Approach 2:
The manufacturing process is segmented into discrete layers that are built sequentially. Each layer is deposited and processed independently, allowing for precise control of material usage and enabling complex geometries without material waste. The energy source is also segmented spatially through scanning patterns that target only the required regions
2Loss of substance
If additive manufacturing is used to build parts layer-by-layer, then material efficiency is improved, but manufacturing speed and productivity decrease
Solution Approach 1:
The patent implements continuous manufacturing by maintaining uninterrupted material supply and energy input throughout the build process. The powder feed system continuously delivers material while the energy source continuously processes each layer, eliminating idle time between operations and maximizing productivity while preserving additive manufacturing's material efficiency
Solution Approach 2:
The system dynamically adjusts processing parameters during manufacturing based on real-time conditions. Energy source power, scanning speed, and powder feed rate are dynamically optimized for each layer and region, enabling faster processing without sacrificing material efficiency or part quality
3Manufacturing precision
If high energy sources (lasers, electron beams) are used for additive manufacturing, then manufacturing precision is improved, but energy consumption increases
Solution Approach 1:
The patent applies energy locally only where material deposition and bonding are required, rather than heating the entire build chamber. The energy source is precisely positioned and focused on the immediate build area, providing high precision with minimal energy waste to surrounding regions
Solution Approach 2:
The energy input is segmented into discrete pulses or scanned paths that match the layer-by-layer build process. Each energy pulse is precisely controlled in duration and intensity, delivering only the necessary energy for local material processing without excess consumption
4Productivity
If rapid cooling occurs after material amalgamation, then manufacturing speed is improved, but structural properties and material strength deteriorate
Solution Approach 1:
The patent applies preliminary heating or thermal conditioning to the build chamber or substrate before material deposition. This preliminary thermal preparation ensures that subsequent rapid cooling produces desired microstructural properties by controlling the initial thermal state, thereby maintaining strength while enabling fast processing
Solution Approach 2:
The system dynamically changes thermal parameters during and after processing. By adjusting cooling rate, hold temperature, and energy input timing as controllable parameters, the patent achieves both rapid manufacturing and optimized material properties through precise thermal parameter management
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 precise control over the additive manufacturing process, improving the structural properties of printed parts by allowing for tailored heat treatment and energy distribution, enhancing manufacturing efficiency and reducing energy costs through energy recycling.
Implementation Method 1
an energy source to emit one or more energy beams
Implementation Method 2
The energy source may include one or more lasers, or an electron beam
Implementation Method 3
absorb the radiant energy, thereby increasing a temperature of the granular material
Implementation Method 4
controlling a cooling rate of the granular material... to produce a desired crystal structure
Data Source
AI summary
An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control the rate of cooling experienced by each successive additive layer. Accordingly, the system may be used to heat treat the various additive layers.