Powder Bed Segmentation for Even Laser Load in Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing methods using powder beds face issues such as localized overheating and uncontrolled cooling due to segmentation of powder bed layers, particularly in edge regions where components protrude beyond neighboring segments, leading to inefficiencies and potential damage.
Innovation Solution
The method employs two-dimensional beam deflection and segmentation lines perpendicular to a gas flow to divide powder bed layers, adapting segmentation lines based on component geometry and melt volume, ensuring equal laser load within segments, and using multiple beams to avoid localized overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the powder bed layer is divided into multiple rigid segments, then the laser beams can be managed in an organized manner, but very short vectors occur in edge regions leading to localized overheating
Solution Approach 1:
The patent transitions from rigid, fixed segmentation lines to dynamic segmentation lines that can adapt their position and orientation. The segmentation lines are no longer static boundaries but are optimized for each specific layer and component geometry, allowing the system to avoid short vectors and overheating while maintaining organized laser beam management.
Solution Approach 2:
The patent applies different segmentation strategies to different regions of the powder bed. Instead of uniform rigid segmentation, the segmentation lines are locally adapted to component geometry, layer characteristics, and thermal conditions, allowing optimal laser path planning in each local region while preventing localized overheating.
2Ease of operation
If the powder bed layer is divided into multiple rigid segments, then the processing can be organized, but many seams are created between neighboring segments leading to uncontrolled cooling
Solution Approach 1:
The segmentation lines become dynamic rather than rigid, adapting to minimize the creation of harmful seams. The system optimizes segmentation line positions to reduce the number of boundaries between segments, thereby minimizing uncontrolled cooling events while preserving processing organization.
Solution Approach 2:
The patent performs preliminary optimization of segmentation lines before actual laser processing. By pre-calculating optimal segmentation line positions that minimize seams and uncontrolled cooling, the system prepares the processing plan in advance, avoiding temperature control issues during execution.
3Device complexity
If segmentation lines are rigid and fixed, then the system is simple to implement, but they cannot adapt to varying component geometry and melt volume
Solution Approach 1:
The segmentation system transitions from static, rigid lines to dynamic, adaptive lines that can change position and orientation based on component geometry, layer characteristics, and processing requirements. This dynamic approach maintains relative system simplicity while achieving high adaptability through algorithmic optimization.
Solution Approach 2:
The patent changes the parameters of segmentation lines dynamically based on component geometry and melt volume. Instead of fixed positions, the segmentation line parameters (position, orientation, spacing) are adjusted according to local geometric features and thermal conditions, enabling adaptation without significantly increasing 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 prevents localized overheating and ensures even utilization of beams, improving productivity and surface quality by optimizing beam interaction and reducing uncontrolled cooling.
Implementation Method 1
a pulverulent material, for example a metal or ceramic powder, is subjected to electromagnetic radiation... solidifying, using the at least two beams, the at least one component to be solidified by means of a substantially equal laser load
Implementation Method 2
multiple segmentation lines running approximately perpendicularly to a direction of a gas flow, wherein the gas flows in a substantially parallel manner over the powder bed
Data Source
AI summary
A method for an additive manufacture of at least one component in layers in a powder bed uses at least two beams which can be deflected two-dimensionally. The method includes: dividing the powder bed including multiple powder bed layers into multiple segments by means of multiple segmentation lines running approximately perpendicularly to a direction of a gas flow, wherein the gas flows in a substantially parallel manner over the powder bed; solidifying, using the at least two beams, the at least one component to be solidified by means of a substantially equal laser load within a segment of a powder bed layer of the multiple powder bed layers; and adapting individual segmentation lines of each powder bed layer based on a criterion.