Scan Velocity Determination Device for Additive Manufacturing
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Solution Overview
Problem
Existing determination devices for additive manufacturing struggle to accurately determine scan velocities of energy beams along non-straight paths and are sensitive to inaccurate positioning, leading to errors in energy deposition and object quality.
Innovation Solution
A determination device that calculates scan velocity based on the time required to guide an energy beam along a closed path of arbitrary shape, using a sensor to generate signals at arbitrary points, allowing for reduced mechanical delays and increased positioning flexibility, with a larger determination area to accommodate errors in positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a straight scan path of known length is used to determine scan velocity, then the measurement can be performed with simple detection elements, but the determination device becomes sensitive to inaccurate positioning and mechanical delays
Solution Approach 1:
The patent applies curvature by using a closed scan path (circular or elliptical) instead of a straight line. The determination element is positioned at any point along this closed path, and the scan velocity is calculated based on the periodic signals generated when the energy beam passes the determination element during complete revolutions. This curved/closed path approach eliminates sensitivity to absolute positioning accuracy while maintaining measurement precision.
Solution Approach 2:
The patent employs periodic action by utilizing multiple complete revolutions of the energy beam along the closed scan path. The determination element generates periodic signals each time the beam passes, and the scan velocity is determined from the time intervals between these periodic signals. This periodic measurement approach improves reliability by averaging out mechanical delays and positioning errors over multiple cycles.
2Measurement precision
If detection elements are positioned precisely inside the process chamber to ensure accurate scan path length, then measurement precision improves, but device complexity and positioning requirements increase
Solution Approach 1:
By implementing a closed scan path where the determination element can be positioned at any point along the path, the system eliminates the need for precise absolute positioning. The geometric properties of the closed path (circumference or perimeter) are used instead of precise relative positioning between multiple detection elements, thereby reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The determination element serves itself by being positioned at any convenient location along the closed scan path. The system uses the periodic passage of the energy beam past this single determination element to self-determine the scan velocity, eliminating the need for complex external positioning systems or multiple precisely positioned detection elements.
3Adaptability or versatility
If the energy beam is guided along a straight path, then the scan velocity determination is straightforward, but velocities for deviant (curved) scan paths cannot be determined
Solution Approach 1:
The determination device achieves universality by being applicable to any closed scan path geometry (circular, elliptical, or other shapes). The single determination element positioned along the closed path can measure scan velocity for any beam guiding mechanism that completes revolutions along this path, making the device versatile for different additive manufacturing systems without increasing complexity.
Solution Approach 2:
The patent explicitly enables determination of scan velocities for curved and complex paths by using a closed scan path approach. The determination element detects the periodic passage of the energy beam regardless of the specific curvature or shape of the path, allowing velocity measurement for deviant scan paths that were previously undeterminable with straight-line methods.
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 enables accurate determination of scan velocity for complex paths, reducing errors in energy deposition and improving object quality by minimizing the impact of mechanical delays and positioning inaccuracies.
Implementation Method 1
The determination device comprises a sensor that is arranged in the process chamber and that generates an electrical signal upon irradiation with the energy beam
Data Source
Figure 1~2
AI summary
Determination device (9) for determining a scan velocity of an energy beam (5) for an apparatus (1) for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy beam (5), wherein the determination device (9) comprises a determination unit (10) that is arrangeable or arranged in a process chamber (7) of an apparatus (1) for additively manufacturing three-dimensional objects, wherein the determination device (9) is adapted to determine a scan velocity with which the energy beam (5) is guided along a closed scan path (14, 14') based on the scan time required for guiding the energy beam (5) along the closed scan path (14, 14').