Shaped Energy Beam Profiles for Low-Stress Additive Layer Fusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing technologies face challenges with thermal stress and reduced production throughput due to thermal gradient generation and high power densities from two-dimensional scanning of focused laser beams, which are not adequately addressed by current techniques that adjust laser beam shapes and intensities.
Innovation Solution
The method involves partially melting and fusing regions of multiple layers with shaped high energy beams, such as laser or electron beams, using diffractive optical elements and obstacles to control beam profiles and energy distribution, allowing for simultaneous formation of entire layers with controlled porosity and attachment, thereby minimizing thermal stress and increasing build rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two-dimensional scanning of focused laser beam is used, then manufacturing precision is improved, but thermal stress increases and production throughput decreases
Solution Approach 1:
The laser beam is segmented into multiple independent beamlets arranged in an array pattern, allowing simultaneous processing of multiple locations across the powder bed. This parallel processing approach maintains precision at each location while dramatically increasing overall production throughput by treating multiple areas concurrently rather than sequentially scanning.
Solution Approach 2:
The invention transitions from two-dimensional scanning (moving beam in X-Y plane) to a three-dimensional approach where multiple beamlets are distributed across the build area in a structured array. This spatial distribution across multiple dimensions enables simultaneous energy delivery to multiple locations, eliminating the sequential scanning bottleneck that limits throughput.
2Manufacturing precision
If two-dimensional scanning of focused laser beam is used, then manufacturing precision is improved, but thermal gradient generation increases
Solution Approach 1:
By segmenting the total energy into multiple smaller beamlets distributed across the layer, the thermal input is spread out spatially rather than concentrated in a single moving spot. This distribution reduces localized thermal gradients and prevents excessive heat accumulation, while still achieving complete layer consolidation through the combined effect of all beamlets.
Solution Approach 2:
The thermal energy distribution transitions from a one-dimensional scanning path to a two-dimensional array of simultaneous energy sources. This multi-dimensional energy distribution creates a more uniform thermal field across the powder bed, reducing steep thermal gradients that cause residual stress and distortion.
3Manufacturing precision
If high power density laser is used, then manufacturing precision is improved, but material vaporization occurs instead of consolidation
Solution Approach 1:
The high power laser beam is divided into multiple lower-power beamlets, each delivering reduced power density to the powder bed. This segmentation prevents the excessive localized heating that causes vaporization, while the cumulative effect of all beamlets still provides sufficient total energy for complete layer consolidation and bonding.
Solution Approach 2:
Each individual beamlet in the array is optimized to deliver appropriate energy density for consolidation without vaporization, while the collective array provides the total energy required for complete layer fusion. This local optimization of energy density at each beamlet position prevents harmful vaporization while maintaining effective consolidation.
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 reduces thermal stress and enhances production throughput by ensuring consistent energy application across layers, allowing for the creation of complex structures with controlled porosity and improved material properties.
Implementation Method 1
an entire first region of a first layer of a first material may be at least partially melted and fused together to form a first component layer
Implementation Method 2
the total energy applied to the second layer of material is sufficient to at least partially re-melt the first layer of the first material
Implementation Method 3
using diffractive optical elements and obstacles to control beam profiles and energy distribution
Data Source
AI summary
A component is fabricated in an additive manufacturing process. Only a portion of a first layer of a first material is at least partially melted to define a first component layer of the component. Only a portion of the second layer of a second material is at least partially melted to define a second component layer of the component in which the entirety of the second component layer is formed simultaneously, and the second component layer is attached to the first component layer.