Additive Manufacturing Solidifying Device Allocation Optimization
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Solution Overview
Problem
In additive manufacturing, particularly for metal objects, effectively processing CAD files into thin layers and generating apparatus settings and vectors for multiple solidifying devices is challenging due to issues like fume and splash disturbances, which affect layer manufacturing throughput and product quality.
Innovation Solution
A method involving a data processing unit that defines and calculates multiple solidifying device allocations, accounting for expected disturbance areas such as fumes and splashes, to determine the longest manufacturing throughput time and select the optimal device allocation for efficient layer production, optimizing the manufacturing process by minimizing idle time and ensuring product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple solidifying devices are used to increase productivity, then layer manufacturing throughput time is reduced, but coordination complexity and calculation complexity for optimal allocation increases
Solution Approach 1:
The patent segments the layer manufacturing process into multiple independent solidifying device allocations, where each device is assigned to specific regions or layers. This segmentation allows parallel processing of different parts of the object, increasing overall productivity while managing complexity through modular allocation strategies.
Solution Approach 2:
The patent changes the allocation parameters dynamically by calculating and comparing multiple solidifying device allocations with different assignments. By varying the allocation parameters (which device processes which region/layer), the system optimizes throughput time without requiring permanent complex coordination structures.
2Loss of time
If solidifying devices operate closer together to reduce idle time, then manufacturing speed increases, but disturbance areas (fume and splash interference) increase
Solution Approach 1:
The patent applies local quality by assigning different solidifying devices to specific local regions or layers where they operate independently. This spatial differentiation allows devices to operate closely in time (reducing idle time) while maintaining sufficient spatial separation or targeted protection in specific local areas to minimize fume and splash interference.
Solution Approach 2:
The patent introduces protective measures as intermediaries between solidifying devices and the material being processed. These intermediaries (such as protective barriers or controlled atmospheric zones) allow devices to operate in close proximity without their disturbance areas interfering with each other, thus maintaining high productivity while reducing harmful effects.
3Manufacturing precision
If more processing parameters are considered for optimal allocation, then product quality improves, but calculation time and data processing complexity increase
Solution Approach 1:
The patent performs preliminary calculations and pre-determines optimal solidifying device allocations before actual manufacturing begins. By calculating multiple allocation scenarios in advance and selecting the optimal one, the system ensures high manufacturing quality without incurring continuous calculation delays during the production process.
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 method improves the effectiveness and speed of the additive manufacturing process by optimizing the allocation of solidifying devices, reducing manufacturing time, and minimizing the impact of fumes and splashes, leading to higher product quality and cost-effectiveness.
Implementation Method 1
a solidifying device for solidifying a layer of the material on the surface level by means of electromagnetic radiation
Data Source
AI summary
The invention relates to a method for manufacturing an object from a material by means of additive manufacturing using a plurality of solidifying devices for solidifying said material in stacked layers by means of electromagnetic radiation. Said method comprises the step of defining, by a data processing unit, at least two solidifying device allocations. In each of said solidifying device allocations said plurality of solidifying devices are allocated to respective parts of said layer such that said parts cover said layer. The method further comprises calculating, by said data processing unit, for each of said at least two solidifying device allocations, respective allocated part manufacturing times representing times for each of said plurality of solidifying devices for solidifying said respective allocated part of said layer, wherein said calculating takes into account an expected disturbance area from solidifying said material by one of said plurality of solidifying devices, wherein said disturbance area relates to at least an expected fume above said layer. The data processing unit then determines the manufacturing throughput time, and selects a definite allocation.