Segmented Irradiation Device for Additive Manufacturing Energy Optimization

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Solution Overview

Problem

Existing additively manufacturing apparatuses for three-dimensional objects using energy beams are inefficient due to high costs and maintenance demands of high-power irradiation units, which require extensive infrastructure and energy for processes that often use more power than needed.

Innovation Solution

An apparatus with an irradiation device featuring multiple individually controllable irradiation elements and a common holding structure, allowing for the combination and separate guidance of energy beams to optimize energy usage, reduce irradiation time, and simplify cooling and energy distribution, using a common energy source and cooling device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-power irradiation units are used to reduce irradiation time, then productivity is improved, but device complexity and operational costs increase due to extensive infrastructure requirements

Engineering Contradiction:

Improveirradiation timeVSAvoidinfrastructure requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The irradiation device is divided into multiple independently controllable irradiation elements instead of using a single high-power source. Each element can be controlled separately, allowing the system to achieve high productivity when needed while avoiding the infrastructure complexity of a single high-power unit through distributed lower-power elements.

Inventive Principle:

Principle #1Segmentation

2Productivity

If high-power irradiation units are used to consolidate build material faster, then productivity is improved, but energy consumption increases

Engineering Contradiction:

Improveconsolidation speedVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

Instead of always using maximum power from a single high-power source, the system applies partial action by using only the necessary number of irradiation elements at any given time. Multiple lower-power elements can be activated selectively to match the actual energy requirements of the build material consolidation process, avoiding excessive energy consumption while maintaining high productivity when needed.

Inventive Principle:

Principle #16Partial or excessive action

3Device complexity

If a single high-power irradiation element is used, then device complexity is reduced, but manufacturing precision decreases due to inability to vary energy parameters across different regions

Engineering Contradiction:

Improveirradiation device structureVSAvoidconsolidation quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The irradiation device is segmented into multiple independently controllable irradiation elements, each capable of being activated or deactivated individually. This segmentation allows different regions of the build plane to receive customized energy parameters, improving manufacturing precision while keeping each individual element relatively simple in design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system implements dynamic control where the activation state of each irradiation element can be changed in real-time based on the specific requirements of different build regions. This dynamic adaptability enables precise control over energy distribution across the build plane, allowing optimization of consolidation quality for different structures without requiring a completely different device configuration.

Inventive Principle:

Principle #15Dynamics

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 solution enables more efficient energy use, reduces irradiation time, and simplifies the infrastructure requirements by allowing only the necessary energy to be applied, improving the consolidation process while maintaining control over beam parameters and reducing operational costs.

Implementation Method 1

irradiation units, such as laser sources, that are adapted to generate a corresponding energy beam

Methodology Applied

Scientific EffectLaser beam energy depletion: Laser

Implementation Method 2

selective irradiation and consolidation of layers with an energy beam... the energy that is depleted in a defined volume of build material influences the consolidation behavior, for example the degree to which the build material is melted, i.e. consolidated

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Implementation Method 3

cooling units... infrastructure provided for these irradiation units

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

cooling units... infrastructure provided for these irradiation units

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP3524409A1Apparatus for additively manufacturing three-dimensional objects

Publication Date: 2019.08.14 CONCEPT LASER

Figure 1

AI summary

Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy source, wherein an irradiation device (4) with at least one irradiation unit (5) is provided that comprises a common holding structure (6), in particular a common housing, holding at least two irradiation elements (7) in a defined spatial relation, wherein the at least two irradiation elements (7) are individually controllable.