Wire-Based Additive Manufacturing System With Parallel Laser Welding
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Solution Overview
Problem
Current laser sintering additive manufacturing processes for metal parts face issues such as unwanted welding, waste of powdered metal, slow processing due to direct laser contact requirements, and limitations in speed and complexity of geometries.
Innovation Solution
A wire-based additive manufacturing system using a movable base with welding and cutting lasers, where wires are fed and fused in a layered manner, allowing for orthogonal orientation and precise control of wire placement, enabling efficient construction of complex geometries without direct laser contact with the entire surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser sintering is used to fuse powdered metal layer by layer, then complex geometries can be manufactured, but the process is slow due to sequential layer application and direct laser contact requirements
Solution Approach 1:
The system segments the manufacturing process by dividing the work into multiple stations (wire feeding, welding, cutting, cleaning) that operate simultaneously on different layers. This parallel processing approach eliminates the sequential bottleneck of traditional laser sintering, where each layer must be completed before the next begins.
Solution Approach 2:
The invention transitions from sequential single-layer processing to multi-layer simultaneous processing by adding the vertical dimension (Z-axis) to the manufacturing process. Multiple layers are built in parallel at different heights, dramatically increasing throughput without requiring faster single-layer processing.
2Productivity
If direct laser contact is used to melt powdered metal, then welding can be achieved, but the entire surface area must be contacted which limits speed
Solution Approach 1:
The system extracts the laser from the direct contact requirement by using wire feeding mechanisms that deliver pre-positioned wire to the welding zone. The laser only needs to contact the wire at specific points rather than scanning the entire surface area, dramatically reducing the time required.
Solution Approach 2:
Wire is pre-fed and positioned in place before the laser welding process begins. This preliminary positioning eliminates the need for the laser to search or contact the entire surface area, as the material is already in the correct location for immediate welding.
3Reliability
If powdered metal is over-applied to ensure coverage, then welding can be achieved, but waste of unused powdered metal increases
Solution Approach 1:
The system applies material with local precision, delivering wire only to the specific locations where welding is required. This eliminates the over-application inherent in powdered metal processes where excess material must be applied to ensure complete coverage, then removed or reclaimed.
Solution Approach 2:
The invention extracts the excess material problem by using wire feeding instead of powdered metal application. Wire can be precisely controlled and applied only where needed, eliminating the waste of unused powdered metal that characterizes the traditional process.
4Manufacturing precision
If sequential layer application is used in laser sintering, then controlled manufacturing is achieved, but the process is slowed by installation and cleaning steps
Solution Approach 1:
The manufacturing process is segmented into specialized stations (wire feeding, welding, cutting, cleaning) that operate in parallel. Each station performs its function independently while maintaining layer control, eliminating the sequential bottleneck where one operation must complete before the next begins.
Solution Approach 2:
The system maintains continuous useful action across multiple layers simultaneously. While one layer is being welded, another is being prepared, and a third is being cleaned, ensuring that no time is lost to sequential transitions and maintaining constant productive activity.
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 enhances manufacturing speed and reduces waste by allowing simultaneous welding of multiple wires, improving the complexity and speed of part creation while minimizing unnecessary material application and processing time.
Implementation Method 1
The at least one welding laser is energized to fuse the first wire to the second wire
Implementation Method 2
the laser sintering process is repeated. In this way multiple additive layers of metal are laser fused
Implementation Method 3
the first cutting laser is energized to cut the first wire and the second cutting laser is energized to cut the second wire
Implementation Method 4
a first mirror redirects a laser welding beam from the at least one welding laser to the first wire and the second wire; and a second mirror redirects a laser cutting beam
Data Source
AI summary
A wire based additive manufacturing system includes a base movable in a feed direction. Multiple welding lasers are each spatially fixed as the base moves in the feed direction. Multiple cutting lasers are each spatially fixed as the base moves in the feed direction. Multiple wire feed members each feed an individual wire of a plurality of wires onto the base as the base moves in the feed direction. Each one the multiple welding lasers is energized to fuse parallel adjoining ones of the plurality of wires, and each one of the cutting lasers is energized to cut one of the fused wires to complete one of a plurality of wire layers.