Tunable Irradiation Module for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing systems lack the ability to optimally adjust parameters such as wavelength bands for different build materials and fusing agents, leading to suboptimal results in terms of material properties and potential degradation due to mismatched radiation exposure.
Innovation Solution
An additive manufacturing device and method that utilize multiple irradiation modules with tunable wavelength bands for both fusing agents and build materials, allowing for selective exposure to optimize the solidification and heating processes, with a first irradiation source tuned for absorption by the fusing agent and a second source for pre-heating the build material, ensuring optimal conditions without overlapping wavelengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single irradiation source with fixed wavelength is used, then the device complexity is low, but the adaptability to different build materials and fusing agents is limited
Solution Approach 1:
The patent implements a dynamic wavelength selection system where the irradiation source can be tuned to different wavelength bands based on the specific build material and fusing agent being used. This allows the system to adapt its radiation characteristics in real-time to match the absorption properties of different materials, resolving the contradiction between adaptability and device complexity by making the wavelength parameter variable rather than fixed
Solution Approach 2:
The system changes the wavelength parameter of the irradiation source to optimize the interaction with different materials. By adjusting the wavelength band to match the absorption characteristics of specific build materials and fusing agents, the system achieves high adaptability without requiring multiple complete irradiation systems, thus managing device complexity while maximizing material versatility
2Manufacturing precision
If the irradiation wavelength is not optimized for the specific material, then the manufacturing process is simple, but the manufacturing precision and material properties deteriorate
Solution Approach 1:
The patent optimizes the wavelength parameter of the irradiation source to match the absorption characteristics of specific build materials and fusing agents. This wavelength optimization ensures maximum energy transfer and precise control over the solidification and heating processes, achieving high manufacturing precision while avoiding material degradation through mismatched radiation exposure
3Object-affected harmful factors
If a broad spectrum irradiation source is used, then the device complexity is low, but harmful degradation of build material occurs
Solution Approach 1:
The patent applies the principle of local quality by matching the irradiation wavelength specifically to the absorption characteristics of the build material and fusing agent. Instead of using a broad spectrum that affects all materials uniformly, the system tailors the radiation wavelength to interact selectively with the intended materials, minimizing harmful degradation while maintaining effectiveness
Solution Approach 2:
The system adjusts the wavelength parameter of the irradiation source to fall within specific bands that are optimally absorbed by the build material and fusing agent. This parameter optimization ensures that energy is deposited where needed without excessive exposure that could cause degradation, resolving the contradiction between protecting materials and managing device complexity
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
Enables the use of a wider range of materials and fusing agents, improving the structural integrity, accuracy, and finish of printed objects by tailoring the radiation exposure to the specific properties of each material, reducing degradation and enhancing the overall manufacturing process.
Implementation Method 1
a first irradiation source having a first wavelength band, the first wavelength band being tuned for absorption by the fusing agent
Implementation Method 2
a second irradiation source having a second wavelength band disposed above the build platform for heating the successive layers of build material
Data Source
AI summary
An additive manufacturing method includes: selecting one of a plurality of irradiation modules based on a selected module having a wavelength band tuned for absorption by a fusing agent to be used to form an object by additive manufacture; plugging the selected module into a socket over the build platform; supporting successive, stacked layers of the object being formed on the build platform; using a liquid dispenser mounted on the carriage, selectively dispensing the fusing agent into an uppermost layer of build material in a pattern corresponding to a layer of the object being formed; and fusing the build material by exposing the fusing agent to a first wavelength band from a first irradiation source in the selected module.