Rotating Build Area Control for Precise 3D Beam Deposition
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Solution Overview
Problem
Existing build systems face challenges in effectively building complex three-dimensional objects with precision and efficiency, particularly in additive manufacturing processes like Laser Metal Deposition, due to limitations in controlling the movement and positioning of build beams and build materials.
Innovation Solution
A build system incorporating an irradiation optical system and a position change apparatus, controlled by a control apparatus, which moves the build beam's irradiation position and changes its positional relationship with the object, allowing for precise formation of build objects along defined movement trajectories using path information to control rotational and scanning directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the build beam irradiation position moves along a simple linear trajectory, then the control system is simple, but the ability to form complex three-dimensional objects is limited
Solution Approach 1:
The patent introduces rotational movement of the build unit area around a rotational axis perpendicular to the object surface, adding a rotational dimension to the traditional linear scanning path. This enables complex three-dimensional object formation by combining linear trajectory movement with rotational orientation changes, allowing the build beam to access and deposit material in complex spatial patterns that cannot be achieved with linear motion alone
2Productivity
If the build unit area moves continuously along the movement trajectory, then the building efficiency is high, but the precision of forming complex geometries decreases
Solution Approach 1:
The patent implements periodic movement of the irradiation position within the build unit area while the build unit area itself moves along the trajectory. This periodic scanning pattern ensures thorough and uniform material deposition across complex geometries, maintaining high precision while the continuous movement of the build unit area preserves building efficiency
3Productivity
If the build beam is supplied continuously to the melt pool, then the building speed is fast, but the precision and quality of the build object deteriorates
Solution Approach 1:
The patent employs periodic supply of the build beam to the melt pool, where the beam is activated and deactivated in a periodic manner during the movement of the build unit area. This periodic activation ensures precise control over material melting and deposition, maintaining high build quality while the continuous movement and periodic beam supply together achieve efficient building speed
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
Enables the formation of complex three-dimensional objects with enhanced precision and efficiency by accurately controlling the build process, allowing for the integration or separation of build objects with workpieces, and facilitating repairs by filling missing parts.
Implementation Method 1
a build apparatus that is configured to build a build object on an object by irradiating a surface of the object with a build beam and supplying a build material to a melt pool that is formed on the object by the build beam
Implementation Method 2
the irradiation optical system includes a deflection optical system that is configured to move, on the surface of the object, an irradiation position of the build beam on the surface of the object by deflecting the build beam
Data Source
AI summary
A build system includes: a build apparatus for building a build object on an object by irradiating a surface of the object with a build beam and supplying a build material to a melt pool that is formed by the build beam; and a control apparatus for controlling the build apparatus, the control apparatus controls the build apparatus so that an irradiation position of the build beam on the surface of the object periodically moves in a build unit area that is set on the surface of the object and the build unit area moves on the surface of the object based on path information that indicates a movement trajectory of the build unit area, and the control apparatus changes, based on the path information, a rotational amount of the build unit area around a rotational axis that intersects the surface of the object.