Synchronized Multi-Laser Additive Manufacturing for Uniform Quality
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Solution Overview
Problem
Current additive manufacturing systems using single laser scanners face limitations in building large parts with uniform quality due to interleaved scanning methods, which can lead to internal strain and mechanical property variations at joints, resulting in reduced part quality and increased build time.
Innovation Solution
The use of a plurality of synchronized laser beams and scanners with overlapping fields of view allows for continuous application of laser energy along a tool path, eliminating the need for interleaved scans and reducing joint issues by ensuring consistent sintering across the part bed, thereby improving build quality and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single laser scanner is used to build large parts, then the device complexity is reduced, but the manufacturing precision and uniformity of quality deteriorate due to interleaved scanning methods causing internal strain and mechanical property variations
Solution Approach 1:
The patent divides the scanning system into multiple independent laser scanners (first scanner, second scanner, etc.), each responsible for specific regions. This segmentation allows simultaneous scanning of different areas without interleaved operations, eliminating internal strain while maintaining quality uniformity across large parts.
Solution Approach 2:
The patent combines multiple laser scanners to operate simultaneously on different regions of the same layer. By merging their capabilities, the system achieves continuous scanning coverage without the quality variations caused by sequential single-scanner operations, resolving the contradiction between device simplicity and manufacturing precision.
2Device complexity
If interleaved scanning methods are used with a single laser, then the device complexity is reduced, but the productivity deteriorates due to increased build time
Solution Approach 1:
The patent implements continuous scanning by deploying multiple laser scanners that operate simultaneously without interruption. Each scanner continuously processes its assigned region, eliminating the start-stop nature of interleaved scanning and significantly reducing build time while maintaining system simplicity.
Solution Approach 2:
By segmenting the scanning task across multiple lasers working in parallel, the system eliminates the sequential time delays inherent in single-laser interleaved scanning. Each scanner independently and continuously processes its portion, achieving high productivity without complex coordination.
3Device complexity
If a single laser beam is used, then the device complexity is reduced, but the productivity deteriorates due to inability to process large areas simultaneously
Solution Approach 1:
The patent segments the processing area into multiple zones, each handled by a dedicated laser beam. This allows simultaneous processing of different regions, dramatically increasing productivity for large parts while keeping each laser's task manageable and the overall system relatively simple.
Solution Approach 2:
By merging multiple laser beams to operate simultaneously on different regions, the system achieves parallel processing capability. This combination of multiple simple laser units delivers the productivity of a complex system without the corresponding complexity increase.
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 enables the production of larger, higher-quality 3D parts with reduced internal strain and eliminates the need for internal and external support structures, enhancing the overall integrity and speed of the additive manufacturing process.
Implementation Method 1
a laser beam draws a cross-section for the layer on the surface of the powder layer, which sinters or melts and solidifies the drawn pattern
Implementation Method 2
selectively sinter or melt layers of powder-based material in a layer-by-layer manner
Implementation Method 3
The movement of the number of laser beams is synchronized to continuously process the selected pattern in each layer
Data Source
AI summary
An additive manufacturing method includes providing a first and second scanners with fields of view that at least partially overlap. The method includes applying a layer of powder-based materials to the part bed and providing a number of laser sources that direct a number of laser beams to the first and second scanners. The laser beams are directed from the scanners to the part bed to selectively fuse the material to produce a layer of a three-dimensional part. The layer is formed by selectively directing laser energy to the material in a selected pattern, and synchronizing the movement of the laser beams to continuously process the selected pattern in each layer of the three-dimensional part. An additive manufacturing system includes first and second laser sources, first and second scanners, and a controller configured to operate the scanners and laser(s) for producing the three-dimensional printed part.