Powder Layer Laminating Molded Object Warp Deformation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing powder layer laminating molding method using lasers struggles to prevent warp deformation in molded objects due to material contraction during the sintering process, particularly in the manufacturing of plate-shaped objects.
Innovation Solution
The method involves dividing the laser irradiation surface into multiple small regions during the sintering process, allowing for reduced contractive force and warp deformation by minimizing the area melted and sintered at once, and optimizing the scanning path to reduce residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the laser irradiates a large area of the powder layer at once during sintering, then the manufacturing efficiency is improved, but warp deformation increases due to material contraction
Solution Approach 1:
The patent applies segmentation by dividing the laser irradiation area into multiple small regions that are sintered sequentially rather than irradiating the entire area at once. This is achieved by controlling the laser to scan and sinter small regions in a predetermined sequence, which reduces the total area subjected to thermal contraction simultaneously, thereby minimizing warp deformation while maintaining reasonable manufacturing efficiency
2Manufacturing precision
If the laser irradiation area is reduced to small regions, then warp deformation is reduced, but the manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by pre-determining the scanning path and sequence of small regions before the sintering process begins. The control system calculates and sets the optimal irradiation sequence in advance, which allows the laser to efficiently traverse the small regions without unnecessary movements or delays, thereby reducing the time penalty associated with segmented irradiation
3Stability of the object's composition
If the powder layer is sintered in small regions, then residual stress is reduced, but the device complexity increases due to scanning path optimization
Solution Approach 1:
The patent applies self-service by implementing an automated control system that autonomously determines and executes the optimal scanning path through algorithmic calculation. The system automatically processes the layer shape data, divides it into small regions, calculates the irradiation sequence, and controls the laser movement without requiring manual intervention or complex external optimization devices, thereby managing the complexity through software-based self-determination
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 effectively reduces warp deformation in molded objects while maintaining structural integrity, allowing for more precise control over the manufacturing process and preventing strength loss.
Implementation Method 1
a second step of sintering the powder layer by irradiating the formed powder layer with a beam having a heating action
Implementation Method 2
a layer laminating structure of a sintered body layer of thermoplastic resin powder
Implementation Method 3
warp deformation of the molded object which is generated due to contraction of a material at the time of laser powder layer laminating molding
Data Source
AI summary
The present invention prevents warp deformation of a molded object formed by laser powder layer laminating molding. There is provided a powder layer laminating molding method including a first step of forming a powder layer which includes powder of a thermoplastic resin, and a second step of sintering the powder layer by irradiating the formed powder layer with a beam having a heating action, in which a molded object is obtained by repeatedly performing the forming and the sintering of the powder layer in the first step and the second step, and an irradiation surface which is irradiated with the beam is divided into a plurality of small regions.