Rotating Powder Bed Additive Manufacturing With Dual Beam Paths
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Solution Overview
Problem
Current additive manufacturing techniques face limitations in building larger three-dimensional objects efficiently without compromising material properties, as they often require longer manufacturing times and are restricted by the static cover area of individual energy beams.
Innovation Solution
The use of multiple energy beams with non-overlapping and overlapping trajectories on a rotating support structure allows for continuous additive manufacturing, enabling the production of larger objects by applying powder layers simultaneously while fusing with one or more energy beams, thereby minimizing interference and optimizing the build area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single energy beam is used for additive manufacturing, then the equipment complexity is low, but the build area is limited and manufacturing speed is slow
Solution Approach 1:
The patent divides the build area into multiple zones by employing multiple energy beam sources (at least two) that operate simultaneously on different portions of the powder layer. Each beam source has its own cover area, and by segmenting the manufacturing process across multiple beams, the effective build area is expanded beyond what a single beam could achieve.
Solution Approach 2:
The patent combines multiple energy beam sources to work together on the same powder layer simultaneously. The beam sources are coordinated to fuse different portions of the powder layer at the same time, merging their individual capabilities to create a larger effective build area and increased manufacturing throughput.
2Productivity
If multiple energy beams are used to expand build area, then manufacturing speed increases, but beam interference occurs
Solution Approach 1:
The patent assigns different operational characteristics to different beam sources based on their local requirements. Each beam source operates independently on its designated portion of the powder layer, allowing for localized optimization of beam parameters (such as power, speed, and pattern) without affecting other beams, thereby minimizing interference while maintaining high productivity.
Solution Approach 2:
The patent employs dynamic control of multiple energy beams where the beam sources can be independently positioned, directed, and adjusted during the manufacturing process. This dynamic coordination allows the system to adapt beam trajectories and parameters in real-time to avoid interference while maximizing the utilization of the build area and manufacturing speed.
3Loss of time
If powder layer application and energy beam fusion are performed sequentially, then process control is simple, but manufacturing time increases
Solution Approach 1:
The patent implements continuous operation by simultaneously performing powder layer application and energy beam fusion in an overlapping manner. While energy beams are fusing one portion of the powder layer, the powder dispenser is already applying the next powder layer in another portion, eliminating idle time and maintaining continuous productive action throughout the manufacturing process.
Solution Approach 2:
The patent applies powder layers in advance in portions that will be processed by energy beams in subsequent or concurrent operations. This preliminary application of powder in specific areas allows the energy beams to immediately begin fusion work without waiting for the entire powder bed to be prepared, thereby reducing manufacturing time while maintaining manageable process control through spatial coordination.
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 method enables the efficient production of larger three-dimensional objects by reducing manufacturing time and maintaining material properties, as the simultaneous application of powder layers and energy beams ensures uninterrupted operation and improved powder layer quality.
Implementation Method 1
directing a first energy beam from a first energy beam source at a first selected location of the powder layer and a second energy beam from a second energy beam source at a second selected location, the first and second energy beam sources causing the powder layer to fuse in the first and second selected locations
Data Source
AI summary
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, comprising the steps of: providing at least one model of said three-dimensional article, moving a support structure in z-direction at a predetermined speed while rotating said support structure at a predetermined speed, directing a first and second energy beam causing said powder layer to fuse in first and second selected locations according to said model, wherein a first cover area of said first energy beam on said powder layer is arranged at a predetermined minimum distance and non-overlapping from a second cover area of said second energy beam on said powder layer, a trajectory of said first cover area and a trajectory of said second cover area are at least one of overlapping each other, abutting each other or separated to each other when said support structure is rotated a full lap.