Shared-Lens Energy Beam Layout for Faster Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing systems, such as Direct Metal Laser Melting, face inefficiencies due to long scanning times for both simple and complex areas, which hinder cost savings and manufacturing efficiency, as they require multiple laser devices that increase energy and mechanical demands.
Innovation Solution
An additive manufacturing system with a consolidating device that uses multiple energy beam generators sharing lenses, where one generator handles large areas and another handles contoured areas, with telecentric lenses and a reflective element to optimize beam direction and reduce the number of passes needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser devices are used to scan different portions of the component surface, then scanning time per layer is decreased, but energy consumption and mechanical requirements increase
Solution Approach 1:
The patent divides the component surface into different zones (simple open areas and complex contoured areas) and assigns different scanning strategies to each zone. This segmentation allows the system to optimize scanning speed for simple areas while using more precise but slower scanning for complex areas, thereby improving overall productivity without requiring multiple laser devices to operate simultaneously at high energy consumption levels.
2Productivity
If multiple laser devices are arranged to scan different portions of the component surface, then scanning time per layer is decreased, but device complexity increases
Solution Approach 1:
The patent makes a single laser device capable of performing multiple functions by equipping it with both a galvanometer scanner for rapid scanning of simple open areas and a telescopic lens for focused scanning of complex contoured areas. This multi-functionality allows one device to replace what would traditionally require multiple specialized devices, thereby improving productivity while reducing system complexity.
3Manufacturing precision
If traditional scanning methods are used for both simple and complex areas, then manufacturing precision is maintained, but manufacturing time increases
Solution Approach 1:
The patent applies different scanning qualities to different regions of the component. For simple open areas, it uses rapid scanning with a galvanometer to cover large distances quickly. For complex contoured areas requiring higher precision, it switches to telescopic lens scanning that provides better focus and control. This local differentiation of scanning quality maintains manufacturing precision where needed while reducing manufacturing time in areas where speed is sufficient.
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 manufacturing time, decreases hardware complexity, and enhances coverage during each pass, thereby improving overall efficiency and cost-effectiveness.
Implementation Method 1
the laser beam or electron beam is directed across a layer of powder to sinter and melt the desired pattern in the layers of the powder bed
Implementation Method 2
the laser beam or electron beam is directed across a layer of powder to sinter and melt the desired pattern
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A consolidating device for an additive manufacturing system is provided. The consolidating device includes at least one first energy beam generator, at least one second energy beam generator, at least one first lens, at least one second lens, and at least one reflective element. The first energy beam generator is configured to generate a first energy beam. The second energy beam generator is configured to generate a second energy beam. The first lens has a first entrance pupil and is positioned between the first energy beam generator and the layer of material. The second lens has a second entrance pupil and is positioned between the first lens and the layer of material. The first entrance pupil and the second entrance pupil substantially overlap. The reflective element is positioned between the first lens and the second lens, and is configured to reflect the second energy beam onto the layer of material.