Selective Postexposure Scanning for Localized Melt Control
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in efficiently addressing varying local energy input requirements during the solidification process, leading to inefficiencies and potential material degradation due to excessive energy input.
Innovation Solution
A method and device that divide the solidification area into sub-regions, applying different energy input parameters to ensure the build material remains above its melting temperature, allowing for localized control of energy input, thereby optimizing mechanical properties and reducing production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the energy required for solidification is supplied to the build material over the entire surface using a surface heater, then the absorption capacity of the build material is increased, but the ability to address different local requirements during solidification is limited
Solution Approach 1:
The solidification area is divided into multiple sub-regions (first sub-region and second sub-region) with different energy input requirements. This segmentation allows the system to apply different energy input parameters to different areas, enabling localized control while maintaining high absorption capacity across the entire surface.
Solution Approach 2:
Different sub-regions are assigned different energy input parameters based on their specific requirements. The first sub-region receives one set of energy input parameters while the second sub-region receives another set, allowing each area to be optimized for its local needs during solidification.
2Reliability
If high-energy laser is used for solidifying scanning of the build material, then the solidification process is effective, but the equipment cost and complexity increase
Solution Approach 1:
The energy input is applied in periodic cycles: first a pre-heating phase where energy is supplied to increase absorption capacity, followed by a solidification phase where energy is supplied to melt and solidify the material. This periodic action allows the use of lower energy densities compared to continuous high-energy laser irradiation, reducing equipment requirements.
Solution Approach 2:
The build material is pre-heated or pre-treated before the actual solidification process to increase its absorption capacity. This preliminary action prepares the material to require less energy during the subsequent solidification phase, reducing the overall energy requirements and equipment complexity.
3Manufacturing precision
If excessive energy input is applied during solidification, then complete melting is achieved, but material degradation occurs
Solution Approach 1:
Different energy input parameters are applied to different sub-regions based on their specific requirements. By adjusting parameters such as energy density, scan speed, and number of passes locally, the system achieves complete melting where needed while avoiding excessive energy input that would cause material degradation in other areas.
Solution Approach 2:
The system applies energy input selectively to only those areas that require it for complete melting, rather than applying uniform excessive energy to the entire surface. This partial action approach ensures adequate melting in critical areas while minimizing unnecessary energy input that would cause degradation.
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 enhances the mechanical properties of the manufactured objects and reduces production time by selectively applying energy input, ensuring complete melting and improved bonding without excessive heating.
Implementation Method 1
solidifying the building material by introducing energy into locations in each layer that are associated with the cross-sections of the objects in this layer by an energy input device for introducing energy into the building material scanning these locations with at least one beam
Implementation Method 2
the energy input parameters for the repeat scan are dimensioned such that the temperature of the building material within the impact area of the beam on the building material is above a melting temperature of the building material
Implementation Method 3
solidifying the building material by supplying radiant energy to locations in each layer that are associated with the cross-sections of the objects in this layer
Data Source
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AI summary
The invention relates to a method for providing control data for an additive manufacture device, having: a first step (S1) of accessing model data: a second step (S2) of generating a data model in which a construction material layer region (51) to be solidified during the production of an object section is specified for a construction material layer, wherein the region (51) to be solidified is divided into a first sub-region (51a) and a second sub-region (51b), and a respective solidification scan of the region (51) locations to be solidified is specified in a data model, said scan solidifying the construction material, and a repeated scan is specified at the locations of the second sub-region (51b) but not at the locations of the first sub-region (51a), the energy input parameter during the repeat scan being measured such that the temperature of the construction material lies above a melting temperature; and a third step (S3) of providing data models generated in the second step (S2) as control data for integrating into a control data set.