Selective Laser Melting Multi-Material Foil Application
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Solution Overview
Problem
The existing selective laser melting (SLM) and electron beam melting (EBM) processes face challenges in applying multiple materials without contaminating the powder bed, which is costly and inefficient when trying to remove and replace different metal powders, limiting the complexity and functionality of 3D articles.
Innovation Solution
The method involves using foils, tapes, or sheets of different materials instead of powders, which are applied and melted using a focused laser or electron beam, allowing for the integration of various materials without contaminating the powder bed, enabling the reuse of expensive powders and improving the welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple metal powders are used to apply different materials, then material variety is improved, but powder bed contamination occurs and costs increase
Solution Approach 1:
The patent segments the material delivery system by providing separate hoppers for different metal powders, allowing selective delivery of specific materials to specific regions without mixing or contamination of the powder bed. This enables multi-material application while maintaining powder purity.
Solution Approach 2:
The invention applies different metal powders to different regions or layers of the substrate selectively. The system allows specific materials to be deposited only where needed on the 3D article, achieving local material property variation without contaminating the entire powder bed.
2Adaptability or versatility
If metal powders are removed and replaced with different materials, then material flexibility is improved, but process time and complexity increase
Solution Approach 1:
The patent prepares different metal powders in advance in separate hoppers, ready for immediate selective delivery. This preliminary organization of materials eliminates the need for time-consuming removal and replacement operations during the manufacturing process.
Solution Approach 2:
The system uses a single SLM device that can handle multiple metal powders simultaneously through multiple hoppers, making the device universal for processing different materials without requiring separate operations or equipment changes.
3Adaptability or versatility
If multiple materials are applied using traditional SLM, then functionality is improved, but powder bed contamination and cost increase
Solution Approach 1:
The invention enables different metal powders to be applied to specific regions or layers of the substrate, allowing local optimization of material properties for different functional requirements while preventing contamination of the overall powder bed.
Solution Approach 2:
By segmenting the powder delivery system into separate hoppers for different materials, the patent enables precise control over which material is delivered to which region, achieving functional differentiation without cross-contamination of powders.
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 allows for the efficient application of multiple materials without powder bed contamination, reducing costs and enhancing product functionality, flexibility, and productivity by enabling the use of different materials on specific sections or contact faces, and facilitating complex geometries and improved heat transfer.
Implementation Method 1
heating it by means of a focused laser or electron beam (ultrasonic welding also possible) to a specified temperature such that the tape, sheet, foil or pre-form, respectively, is at least partly, preferably essentially completely molten by the laser or electron beam
Implementation Method 2
heating it by means of a focused laser or electron beam (ultrasonic welding also possible) to a specified temperature such that the tape, sheet, foil or pre-form, respectively, is at least partly, preferably essentially completely molten by the laser or electron beam
Implementation Method 3
heating it by means of a focused laser or electron beam (ultrasonic welding also possible) to a specified temperature
Implementation Method 4
a first layer of powder that can be sintered is deposited and the powder is sintered according to the layer areas of the part to be manufactured
Implementation Method 5
a first layer of powder that can be sintered is deposited and the powder is sintered according to the layer areas of the part to be manufactured
Implementation Method 6
selective laser melting (SLM), or electron beam melting (EBM)
Data Source
Figure 1a~1d
Figure 2a~2m
AI summary
Disclosed is a method for manufacturing an article (1), particularly a prototype of a product or component, a tool prototype or spare part, by using selected laser melting. Specifically, for the application onto the article (1) of a layer (13) or portion of a second metallic material, which is different from the material of the first metallic powder (4), a tape (12), sheet (14), foil or three-dimensional pre-form (18) of a second material is applied to the article (1) and is heated by means of a focused laser or electron beam (6) to a specified temperature such that the tape (12), sheet (14), foil or pre-form, respectively, are molten by the or electron laser beam (6), wherein the focused beam (6) is applied to a given area corresponding to a selected cross-sectional area of the model of the article (1) under formation of a new layer or part made of second material integral with the article (1).