Selective Laser Melting with Segmented Multi-Laser Array
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Solution Overview
Problem
Conventional selective laser melting (SLM) methods are time-consuming for producing large components due to the point-like impact area of the laser beam, which limits productivity when creating complex geometries without the need for molds.
Innovation Solution
A method and device utilizing multiple lasers arranged next to each other to create an elongated rectangular impact field, allowing for selective switching of lasers to efficiently irradiate larger areas, reducing the path length and enabling faster melting of large areas by guiding the laser head along fixed trajectories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser beam with point-like impact area is used for selective laser melting, then manufacturing precision is maintained, but productivity deteriorates due to time-consuming irradiation of large areas
Solution Approach 1:
The single laser beam is segmented into multiple laser beams (at least two) that are arranged adjacent to each other. Each laser beam can be independently controlled and switched on or off, allowing simultaneous irradiation of multiple points along a linear extension, thereby melting larger areas faster while maintaining precision through selective activation of individual beams.
Solution Approach 2:
The laser irradiation transitions from a point-like impact area to a line-like impact area by arranging multiple laser beams in a linear extension. This dimensional change from 0D point to 1D line enables covering larger areas more efficiently while maintaining the ability to selectively activate specific segments.
2Productivity
If multiple lasers are arranged to create an elongated rectangular impact field, then productivity is improved by rapid melting of large areas, but device complexity increases
Solution Approach 1:
The laser system is divided into multiple independent laser beams that can be selectively activated. This segmentation allows the system to handle complex geometries by turning specific beams on or off while keeping the overall device structure relatively simple and linear.
Solution Approach 2:
The laser beams are arranged to be movable relative to each other or to the building platform, enabling dynamic adjustment of the irradiation pattern. This dynamic capability allows the system to adapt to different component geometries and maintain productivity while managing device complexity through flexible positioning rather than fixed complex arrangements.
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 significantly accelerates the productivity of SLM by allowing for the rapid melting of large areas and the generation of complex geometries, reducing production time and enabling the creation of components with thousands of layers within a day.
Implementation Method 1
Laser radiation is used to completely remelt the powder particles locally. By fusing the powder particles, the powder particles are also fused to a layer lying therebelow.
Implementation Method 2
selective laser melting (SLM) and the similar selective laser sintering. Here, the material to be processed is applied as a powder in one layer on a platform or a material layer.
Data Source
AI summary
A method for producing a component by selective laser melting, wherein a number of lasers arranged next to one another generate a laser field, as a result of which powdery material can be melted in a selective manner for the purposes of generating contours. In the process, individual lasers of the laser arrangement can be switched on or off in a selective matter in order to irradiate or not irradiate certain regions. Furthermore, a device for carrying out the method is provided.