Additive Manufacturing Scan Line Spacing Optimization
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Solution Overview
Problem
Additive manufacturing of three-dimensional articles with small dimensions often results in porosities and incomplete fusion due to shorter scan line lengths, leading to degraded material characteristics.
Innovation Solution
Adjusting the distance between adjacent scan lines based on the length of the scan lines to optimize fusion temperature equilibrium, with shorter scan lines having closer spacing and longer scan lines maintaining constant spacing, to prevent porosities and incomplete fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shorter scan line lengths are used for fusing small dimensions, then manufacturing speed is improved, but material characteristics deteriorate due to porosities and incomplete fusion
Solution Approach 1:
The patent applies parameter changes by adjusting the distance between adjacent scan lines based on scan line length. For shorter scan lines (below predetermined value), a first distance is used, while for longer scan lines (above predetermined value), a second distance is used. This dynamic parameter adjustment ensures complete fusion and eliminates porosities while maintaining manufacturing efficiency across different dimension scales.
2Loss of time
If shorter scan line lengths are used, then production time is reduced, but fusion completeness deteriorates leading to porosities
Solution Approach 1:
The patent implements parameter changes by establishing a relationship between scan line length and distance between adjacent scan lines. When scan line length is below a predetermined value, a first distance is applied; when above, a second distance is applied. This ensures that even with shorter scan lines that reduce production time, the fusion completeness is maintained by optimizing the spacing between scan lines.
3Device complexity
If constant distance between adjacent scan lines is used, then process simplicity is maintained, but material properties vary for different scan line lengths
Solution Approach 1:
The patent applies parameter changes by making the distance between adjacent scan lines dependent on the scan line length. Instead of using a constant distance, the system adjusts the distance parameter based on whether the scan line length is above or below a predetermined value. This ensures consistent material properties and complete fusion across different scan line lengths while maintaining relatively simple process control.
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 eliminates porosities and incomplete fusion, maintaining material properties and improving manufacturing speed and control over microstructure and tensile strength.
Implementation Method 1
a ray gun for delivering energy to the powder whereby fusion of the powder takes place
Implementation Method 2
successive fusion of chosen parts of powder layers applied to a work table
Data Source
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AI summary
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, the method comprising the steps of: providing a model of the at least one three- dimensional article; applying a first powder layer on a work table; directing a first energy beam from a first energy beam source over the work table causing the first powder layer to fuse in first selected locations according to corresponding models to form a first cross section of the three-dimensional article, where the first energy beam is fusing at least a first region of a first cross section with parallel scan lines in a first direction; varying a distance between two adjacent scan lines, which are used for fusing the powder layer, as a function of a mean length of the two adjacent scan lines.