Selective Build Strategy Modification in Additive Manufacturing

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Solution Overview

Problem

Current additive manufacturing techniques lack the ability to readily modify build strategy parameters for specific regions of an object, leading to potential issues such as increased surface roughness and altered material properties in sensitive areas, which cannot be easily controlled or customized.

Innovation Solution

A computerized method and system that allow users to manually select and modify build strategy parameters in specific regions of an object code, enabling customization of parameters like stitching region location, size, and shape, as well as scan vector adjustments, to control the operation of additive manufacturing systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated build strategy parameters are used for the entire object, then manufacturing efficiency is improved, but surface finish and material properties in sensitive areas deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsurface finish

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent enables different build strategy parameters to be applied to different regions of the object. Sensitive areas can have customized parameters (e.g., reduced scan speed, modified hatch spacing) while non-sensitive areas use standard automated parameters, thus achieving high surface finish in critical regions without sacrificing overall manufacturing efficiency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The build strategy is segmented into multiple regions with different parameter sets. The system divides the object into zones based on sensitivity requirements, allowing independent optimization of each zone's manufacturing parameters while maintaining automated operation across the entire object.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If automated build strategy parameters are used for the entire object, then device complexity is reduced, but adaptability to different object features deteriorates

Engineering Contradiction:

Improvesystem complexityVSAvoidcustomization capability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The build strategy parameters are made dynamic and region-specific rather than static and uniform. The system automatically adapts parameters based on the spatial location and sensitivity characteristics of different object features, providing high adaptability while maintaining automated operation without requiring complex manual intervention.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If uniform build strategy parameters are applied, then manufacturing process simplicity is improved, but manufacturing precision in sensitive areas deteriorates

Engineering Contradiction:

Improveprocess simplicityVSAvoiddimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The system applies the principle of local quality by allowing different build strategy parameters (such as laser power, scan speed, hatch spacing) to be specified for different regions of the object. This enables high dimensional accuracy and surface quality in sensitive areas while maintaining simple automated manufacturing processes through software-based parameter differentiation rather than physical process changes.

Inventive Principle:

Principle #3Local quality

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

Enables precise customization of build strategies for specific object features, improving surface finish and material properties in sensitive areas, allowing for more accurate and tailored manufacturing processes.

Implementation Method 1

The melting may be performed by a high powered irradiation beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal

Methodology Applied

Scientific EffectLaser melting: Laser

Implementation Method 2

The melting may be performed by a high powered irradiation beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS10406633B2Selective modification of build strategy parameter(s) for additive manufacturing

Publication Date: 2019.09.10 GE INFRASTRUCTURE TECH LLC

AI summary

A computerized method, system, program product and additive manufacturing (AM) system are disclosed. Embodiments provide for modifying object code representative of an object to be physically generated layer by layer by a computerized AM system using the object code. The computerized method may include providing an interface to allow a user to manually: select a region within the object in the object code, the object code including a plurality of pre-assigned build strategy parameters for the object that control operation of the computerized AM system, and selectively modify a build strategy parameter in the selected region in the object code to change an operation of the computerized AM system from the plurality of pre-assigned build strategy parameters during building of the object by the computerized AM system.