Rotating DMLM Build Plate for Concurrent Powder Deposition and Welding
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Solution Overview
Problem
Conventional DMLM systems face issues such as sequential powder deposition and welding phases leading to system latencies, excess metal powder utilization, and slow build rates, particularly in traditional stationary systems.
Innovation Solution
A rotating DMLM system with concurrent powder deposition and welding operations on a rotating build plate, utilizing a laser scanner mounted above the build plate that translates over the rotating surface to perform simultaneous powder deposition, smoothing, and welding, coordinated by a controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential powder deposition and welding phases are used in traditional DMLM systems, then system simplicity is maintained, but system latencies increase and productivity decreases
Solution Approach 1:
The patent implements continuous useful action by enabling simultaneous powder deposition and welding operations through a rotating build plate mechanism. The build plate rotates to bring different sectors into position: one sector receives powder while another undergoes welding, eliminating idle time between deposition and welding phases. This continuous operation eliminates system latencies and significantly improves build rates without requiring complex multi-axis moving components.
Solution Approach 2:
The build plate is divided into multiple independent sectors, each capable of performing different operations simultaneously. Some sectors are dedicated to powder deposition while others are dedicated to welding operations. This segmentation allows parallel processing of different manufacturing steps, improving overall productivity while maintaining relative simplicity of each individual sector.
2Productivity
If traditional stationary DMLM systems are used, then device complexity is low, but excess metal powder utilization occurs and build rates are slow
Solution Approach 1:
The rotating build plate enables continuous welding operations without waiting for powder deposition to complete, as welding can occur on sectors that have already received powder. This eliminates idle time and accelerates the build rate, allowing faster production while maintaining precise powder utilization through controlled deposition in only the sectors that need material.
Solution Approach 2:
Powder is deposited in advance on specific sectors of the build plate before those sectors enter the welding zone. This preliminary powder placement ensures that material is ready and positioned exactly where needed, minimizing powder waste by avoiding deposition in areas that will not be welded in the current build cycle.
3Productivity
If a laser scanner is mounted over a rotating build plate, then simultaneous powder deposition and welding operations are achieved, but device complexity increases
Solution Approach 1:
The laser scanner is mounted above the rotating build plate and tracks specific sectors as they pass through the welding zone. This configuration allows continuous welding operations to proceed without interruption, as the scanner follows the rotation and maintains precise positioning on the target sector. The system achieves parallel operation of powder deposition and welding, dramatically improving build rates.
Solution Approach 2:
The system incorporates dynamic elements including the rotating build plate and the tracking laser scanner that adjusts its position to follow the rotation. This dynamic configuration enables flexible, high-speed manufacturing by continuously adapting the welding position to match the rotating substrate, allowing simultaneous deposition and welding operations.
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 reduces system latencies, improves build times, and allows for the construction of larger and more objects in a given time period, enabling faster and more efficient additive manufacturing.
Implementation Method 1
The powder is heated to melting by a laser, such as a high-energy fiber laser, under the control of a computer. The melted powder cools and solidifies to form one layer of the object
Data Source
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AI summary
A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.