Tilted Electron Beam Powder Bed Fusion for Larger Build Volume
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in increasing build volume while maintaining the quality of the energy beam spot, leading to difficulties in forming larger three-dimensional articles due to the need for higher beam power and deflection angles.
Innovation Solution
The method involves using a central non-deflected electron beam tilted at a specific angle to build multiple three-dimensional articles on separate platforms, allowing the electron beam source to change position once and maintain beam quality, thereby increasing the build area without sacrificing spot quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If higher beam power and deflection angles are used to increase build volume, then larger three-dimensional articles can be formed, but beam spot quality deteriorates
Solution Approach 1:
The patent introduces a second build platform positioned above the first build platform, utilizing the vertical dimension to expand build volume. The electron beam source is movable between the first and second build platforms, allowing sequential fabrication on multiple levels without compromising beam spot quality on either platform.
2Area of stationary object
If the electron beam source is rotated or tilted between positions to build on multiple platforms, then build area increases, but device complexity and operation difficulty increase
Solution Approach 1:
The electron beam source is designed with movable positioning capability, allowing it to dynamically transition between different build platforms. This dynamic positioning system simplifies the overall device architecture compared to fixed tilted sources while maintaining the ability to access multiple build areas.
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 larger build volumes with improved manufacturing efficiency and reduced total time by allowing simultaneous or sequential building on multiple platforms with controlled beam positioning, maintaining beam quality and reducing the need for frequent position changes.
Implementation Method 1
an electron beam source emitting a deflectable electron beam causing a first powder layer to fuse
Implementation Method 2
causing a first powder layer to fuse in first selected locations according to the model
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, the method comprising the steps of: providing a model of the at least one three dimensional article; applying a first powder layer on at least one build platform; directing an electron beam from an inclined electron beam source over the at least one build platform where a central electron beam emanating from the source is building an angle α with respect to a normal to the build platform ≠0º, the directing of the first energy beam causing the first powder layer to fuse in a first selected locations according to the model; rotating or tilting the electron beam source a predetermined angle, directing the electron beam from the tilted or rotated electron beam source causing a first powder layer to fuse in a second selected locations according to the model.