Sheet-Based Additive Manufacturing Using Laser-Fused Stacked Sheets
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Solution Overview
Problem
Conventional additive manufacturing techniques face challenges in producing parts efficiently in terms of time, cost, and energy, and often result in poor surface finishes and the need for complex support structures, especially for parts with complex geometries.
Innovation Solution
A method and system that utilize sheets of fusible material, where a laser beam is directed to fuse adjacent sheets according to a predetermined pattern, forming a monolithic construction with improved surface finish and reduced need for support structures by scoring and removing unfused portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing techniques use powder or wire-fed materials, then parts can be produced with complex geometries, but the production is time-consuming, costly, and energy-intensive with poor surface finishes
Solution Approach 1:
The patent changes the material form parameter from powder/wire to sheets, and changes the processing method parameter from layer-by-layer deposition to selective fusion of pre-stacked sheets. This parameter change enables better surface finish quality while reducing production time and energy consumption.
Solution Approach 2:
The patent applies preliminary action by pre-stacking multiple sheets in the desired configuration before applying the fusion process. This eliminates the need for gradual layer-by-layer construction, significantly reducing production time while maintaining complex geometry capability.
2Adaptability or versatility
If conventional additive manufacturing uses support structures for complex geometries, then parts with complex shapes can be manufactured, but the device complexity and material waste increase
Solution Approach 1:
The patent applies segmentation by dividing the part into multiple thin sheets that are stacked and selectively fused. This segmentation approach enables complex geometries to be built without support structures, as each sheet maintains its structural integrity independently before fusion.
Solution Approach 2:
The patent transitions from conventional three-dimensional layer-by-layer construction to a approach that utilizes the sheet stacking dimension. By pre-stacking sheets in the desired configuration and then selectively fusing them, the method eliminates the need for support structures while maintaining complex geometry capability.
3Productivity
If conventional additive manufacturing processes are used, then parts can be produced, but energy consumption and production costs are high
Solution Approach 1:
The patent applies preliminary action by pre-stacking all sheets in the desired configuration before the fusion process begins. This eliminates the need for continuous material feeding and positioning operations, significantly reducing energy consumption and improving production efficiency.
Solution Approach 2:
The patent extracts the material stacking operation from the fusion process, performing stacking separately and independently before fusion. This separation enables more efficient energy utilization during the fusion stage, as the system only needs to heat and fuse specific regions rather than continuously managing material deposition.
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 time, cost, and energy efficiency while improving surface finish quality and reducing the requirement for complex support structures, enabling the production of parts with complex geometries.
Implementation Method 1
directing a laser beam through at least one sheet of the stack... Transferring energy from the laser beam to multiple locations on at least one interface between adjacent sheets of the stack... to form corresponding multiple molten regions
Implementation Method 2
to form corresponding multiple molten regions, conjoined together to form a fused portion of the adjacent sheets
Implementation Method 3
focusing the laser beam at the multiple locations... The focused portion of the laser beam is focused at multiple locations on at least one interface between adjacent sheets of the stack
Data Source
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AI summary
A method (300) of fabricating a part (130), the method (300) comprising: stacking sheets (122) of fusible material to form a stack (120); directing (304) a laser beam (116) through at least one sheet of the stack (120); and transferring energy from the laser beam (116) to multiple locations on at least one interface (124) between adjacent sheets (122) of the stack (120), according to a predetermined pattern corresponding with a design of the part (130), to form corresponding multiple molten regions (128), conjoined together to form a fused portion (127) of the adjacent sheets (122), wherein the fused portion (127) of the adjacent sheets (122) defines the part (130).