Segmented Build Plate Layout for Multi-Beam Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing systems require significant setup time to adjust multiple energy sources and material supplies for accurate positioning on a build surface, leading to inefficiencies in producing multiple identical components.
Innovation Solution
A forming system with a build plate segregated into non-overlapping zones, each associated with a high-energy beam provider, and using datums for precise alignment and separation, allowing simultaneous energy application and easy separation of build zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple energy sources and material supplies are used to produce multiple identical components simultaneously, then productivity increases, but setup time and adjustment complexity increase significantly
Solution Approach 1:
The build plate is divided into multiple non-overlapping build zones, with each zone associated with a separate energy source and material supply. This segmentation allows each zone to be independently configured and processed, enabling simultaneous production of multiple components while maintaining independent adjustment capabilities that reduce overall setup time.
Solution Approach 2:
Build zones are pre-defined with boundaries and associated energy sources are pre-positioned on the build plate before the additive manufacturing process begins. This preliminary arrangement of energy sources and material supplies eliminates the need for time-consuming adjustments during production, as everything is pre-configured for simultaneous operation.
2Productivity
If multiple energy sources are positioned on a common substrate to build multiple components, then manufacturing density increases, but alignment accuracy and positioning precision deteriorate
Solution Approach 1:
The build plate is segmented into multiple non-overlapping build zones, each with clearly defined boundaries. This segmentation provides distinct operational areas for each energy source, eliminating interference between adjacent zones and ensuring that each energy source maintains precise alignment within its designated zone while contributing to high manufacturing density.
Solution Approach 2:
Each build zone is configured with local characteristics including specific boundary definitions and associated energy sources positioned optimally for that zone. This local optimization allows each energy source to achieve high positioning precision within its own zone while the overall system maintains high manufacturing density through the coordinated arrangement of multiple zones.
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
Facilitates efficient production of multiple identical components with improved alignment accuracy and reduced setup time, enhancing manufacturing density and safety.
Implementation Method 1
Each high-energy beam provider may generate a laser beam, electron beam or other high-energy beam capable of melting the material used to form the one or more datums and the one or more articles
Implementation Method 2
Each high-energy beam provider may generate a laser beam, electron beam or other high-energy beam capable of melting the material used to form the one or more datums and the one or more articles
Implementation Method 3
Each high-energy beam provider may comprise a mirror or other reflecting device to reflect a laser beam, electron beam or other high-energy beam capable of melting the material
Data Source
AI summary
A method of forming a plurality of components on a build-plate, the method comprising the steps of providing a forming system comprising a plurality of high-energy beam generators mounted on a common support and configured to direct energy onto the build-plate; the build-plate comprising at least one segregation zones segregating the build plate into a plurality of build zones, each build zone associated with one of the high-energy beam generators; forming within each build zone at least one datum from material melted by energy from its associated high-energy beam generator; and forming within each build zone at least one component from material melted by energy from its associated high-energy beam generator; cutting or machining the build plate at the segregation zone or segregation zones to separate the build zones.