Scan Field Boundary Coordination in Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing, the melting behavior of building material at the boundary regions of exposure zones from different laser beams is inconsistent, leading to inhomogeneities and degraded mechanical properties.
Innovation Solution
A computer-aided method generates a control data set for an energy input device to coordinate the scanning of locations in adjacent subregions, ensuring that locations on both sides of the boundary are solidified at a time coordinated with each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beams are used simultaneously to solidify different sections of a layer, then productivity is improved, but manufacturing precision deteriorates at boundary regions due to inhomogeneous melting behavior
Solution Approach 1:
The patent applies preliminary action by coordinating the scanning trajectories and timing of multiple laser beams before they reach the boundary regions. The control system pre-calculates and synchronizes the exposure timing so that adjacent sections are solidified simultaneously or in a controlled sequence, preventing the time-lag induced inhomogeneities at boundaries while maintaining high productivity through parallel processing
2Device complexity
If locations in adjacent subregions are scanned with a time lag, then device complexity is reduced, but manufacturing precision deteriorates due to inhomogeneities at boundary lines
Solution Approach 1:
The patent implements feedback by continuously monitoring the solidification process and dynamically adjusting the scanning parameters of multiple laser beams. The control system receives information about the state of each section and modifies the timing and trajectories of subsequent scans to ensure that boundary regions receive coordinated exposure, maintaining manufacturing precision while allowing for practical device complexity constraints
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 improves the quality of the manufactured objects by reducing local shrinkage and inhomogeneities at the boundary regions, resulting in more homogeneous and mechanically robust products.
Implementation Method 1
solidifying the building material in a build area by means of the energy input device by supplying radiation energy to solidification positions
Implementation Method 2
supplying thermal energy to the building material by irradiating it with electromagnetic radiation or particle radiation (e.g. laser sintering (SLS) or laser melting (SLM))
Implementation Method 3
Solidification can be achieved, for example, by supplying thermal energy to the building material by irradiating it with electromagnetic radiation or particle radiation
Implementation Method 4
the melting behavior or solidification behavior of the building material is slightly different
Data Source
AI summary
Disclosed is a method for generating a control data set for an energy input device of an additive manufacturing device. The method includes accessing computer-based model data of an object cross-section of the object to be manufactured, and generating a data model of a region of a building material layer to be solidified, where the region to be solidified is divided into a plurality of subregions. At least a first subregion and a second subregion adjoin each other at a boundary, and locations in the first subregion are scanned at a time coordinated with locations in the second subregion Further, the control data set for the energy input device is generated taking into account the data model generated previously.