Rotating Beam Additive Manufacturing for Higher Build Rates
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Solution Overview
Problem
Additive manufacturing methods, particularly those using laser beams, face challenges in cost-effectiveness and efficiency due to low build rates and high component costs, along with issues like residual porosity and loss of material, limiting their application in high-volume production.
Innovation Solution
The method involves using a rotational base element with centrifugal acceleration to hold the starting material, allowing for rotational movement of the energy beam irradiation means, which enables varying relative velocities and intensities, and adjusts the angular velocity to influence powder dynamics and process parameters, such as pore formation and gas stream interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used for high-volume production, then production capacity increases, but cost-effectiveness deteriorates due to low build rates
Solution Approach 1:
The patent applies rotational dynamics by rotating the base element with the starting material at controlled angular velocities. This dynamic approach enables the energy beam to process multiple locations on the rotating base element sequentially, significantly increasing the build rate and production capacity while maintaining cost-effectiveness through efficient material utilization
Solution Approach 2:
The rotational movement of the base element allows continuous processing without interruption. The energy beam continuously irradiates different sections of the rotating starting material, eliminating idle time between processing steps and maintaining continuous productive action throughout the manufacturing cycle
2Reliability
If gas stream is used to prevent oxidation, then protection of starting material improves, but material loss increases due to powder being blown away
Solution Approach 1:
The patent applies local quality by directing the gas stream only at specific locations where oxidation protection is needed, rather than uniformly across the entire processing area. The gas flow is localized to the energy beam interaction zone, protecting the starting material from oxidation while minimizing disturbance to surrounding powder and reducing material loss
Solution Approach 2:
The rotational movement of the base element dynamically changes the position of the starting material relative to the gas stream direction. This dynamic configuration allows the gas to protect the material effectively while the rotation prevents excessive powder accumulation or blowaway in any single location, reducing overall material loss
3Extent of automation
If rotational movement of energy beam irradiation means is implemented, then process control improves, but device complexity increases
Solution Approach 1:
The patent merges the rotational movement function into the existing base element that already supports the starting material. By combining the support function and rotational drive function into a single integrated base element, the system achieves enhanced process control through rotation without adding separate complex rotational mechanisms for the energy beam
Solution Approach 2:
Instead of rotating the energy beam irradiation means to achieve process control, the patent inverts the approach by rotating the base element with the starting material. This inversion simplifies the device architecture while achieving the same process control objectives through relative motion between the energy beam and material
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 enhances process control and efficiency by reducing material loss, improving surface quality, and allowing for the production of complex components with reduced porosity and increased throughput, making additive manufacturing more viable for high-volume production.
Implementation Method 1
wherein the starting material is held on the base surface by a centrifugal acceleration generated by the rotational component
Implementation Method 2
a component is produced in layers using an energy beam which solidifies a starting material and is irradiated by energy beam irradiation means
Data Source
AI summary
The invention relates to an additive manufacturing method in which a component (10, 42, 43, 44, 45) is produced in layers using an energy beam (8, 41, 58) which solidifies a starting material (4) and is irradiated by energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61) while the starting material (4) is held by a base surface (3, 15, 30, 36, 52) arranged on a base element (2, 16, 29, 35, 51). While the starting material (4) is being irradiated with the energy beam (8, 41, 58), the base element (2, 16, 29, 35, 51) is moved by a rotational component which has a base element rotational axis, wherein the starting material (4) is held on the base surface (3, 15, 30, 36, 52) by a centrifugal acceleration generated by the rotational component. The invention is characterized in that a rotational movement is produced for at least some of the energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61). Analogously, at least one energy beam rotational axis (46) is proposed for rotating at least some of the energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61) in an additive manufacturing device in which the starting material (4) is held on a base surface (3, 15, 30, 36, 52) by a centrifugal acceleration.