3D Printing Scan Stripe Layout to Prevent Linear Defect Chains
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Solution Overview
Problem
Existing additive layer manufacturing techniques often result in linearly arranged defects or pores due to suboptimal setting of stripe offsets and changes in melt pool size, leading to mechanical weaknesses in the workpiece.
Innovation Solution
Define scanning vectors within an irradiation section such that they are parallel or substantially parallel, with angles differing from 90 degrees, and vary the locations of irradiation energy density changes to avoid linear arrangements of defects or pores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stripe offset is set to create distance between stripes, then manufacturing speed is improved, but linear defect chains form when overlap or distance is too large
Solution Approach 1:
The patent applies preliminary action by pre-calculating and optimizing the stripe offset value before the additive manufacturing process begins. The system determines the optimal offset that prevents linear defect chain formation while maintaining efficient manufacturing speed, thereby avoiding defects before they occur rather than detecting or correcting them during production.
Solution Approach 2:
The patent employs parameter changes by dynamically adjusting the stripe offset parameter based on melt pool size measurements and environmental conditions. The system monitors process parameters in real-time and modifies the stripe offset to maintain optimal values that prevent linear defect chains while preserving manufacturing productivity.
2Strength
If melt pool size increases due to environmental influences, then material fusion is improved, but linear defect chains form when overlap or distance between stripes is not optimally set
Solution Approach 1:
The patent implements feedback mechanisms by continuously monitoring melt pool size and environmental parameters during the additive manufacturing process. The system uses this feedback information to dynamically adjust the stripe offset parameter, ensuring that linear defect chains are prevented even when melt pool size varies due to environmental influences such as gas flow changes or pressure fluctuations.
Solution Approach 2:
The patent applies dynamics by making the stripe offset parameter adaptive rather than static. The system continuously adjusts the stripe offset based on real-time measurements of melt pool size and environmental conditions, allowing the process to respond dynamically to changes and maintain optimal quality without forming linear defect chains.
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 improves the quality of three-dimensional workpieces by preventing linear defect chains, enhancing mechanical properties and reducing the impact of environmental influences on the manufacturing process.
Implementation Method 1
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 2
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 3
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Data Source
AI summary
We describe a method comprising: defining an irradiation section, in particular an irradiation stripe, on a material layer to be irradiated, in an additive layer manufacturing process, with an irradiation beam scanned across the material layer, and defining, within the irradiation section, two or more parallel or substantially parallel scanning vectors for said scanning of a said irradiation beam across the material layer, wherein all scanning vectors within the irradiation section are parallel or substantially parallel with respect to each other, wherein, based on said defining of the two or more parallel or substantially parallel scanning vectors, a line results which connects a first location, on the material layer, of a change in irradiation energy density of a said irradiation beam for a first one of the two or more parallel or substantially parallel scanning vectors and a second location, on the material layer, of a change in irradiation energy density of a said irradiation beam for a second one of the two or more parallel or substantially parallel scanning vectors, wherein the first scanning vector and the second scanning vector are neighboring scanning vectors, wherein a distance between the first location and the second location is smaller than (i) a distance between the first location and a third location of a change in irradiation energy density of a said irradiation beam for the second one of the two or more parallel or substantially parallel scanning vectors and/or (ii) a distance between the second location and a fourth location of a change in irradiation energy density of a said irradiation beam for the first one of the two or more parallel or substantially parallel scanning vectors, and wherein an angle, which differs from 90 degrees (a) irrespectively of a geometry of a workpiece to be produced using the additive layer manufacturing process, and (b) irrespectively of an orientation of the two or more parallel or substantially parallel scanning vectors with respect to an orientation of the irradiation section, is formed (i) between the first scanning vector and the line, and/or (ii) between the second scanning vector and the line.