3D Work Piece Microstructure Coding Without Hollow Cavities
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Solution Overview
Problem
Existing methods for incorporating information codes into three-dimensional work pieces generated by selective laser melting or sintering are either time-consuming or compromise the mechanical stability of the work piece, often requiring additional materials or post-processing steps.
Innovation Solution
A method and apparatus that control the microstructure of the work piece during generation by selectively applying and irradiating raw material powder to embed an information code pattern directly into the work piece's microstructure, using a single type of powder and avoiding hollow cavities, thus ensuring stability and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the work piece is provided with an information code during generation using selective laser melting/sintering, then the information code can be embedded directly into the work piece, but hollow cavities are created that impair mechanical stability
Solution Approach 1:
The patent changes the physical parameters of the laser processing by using controlled undermelting (reducing laser energy input) to create distinct microstructural zones (fully melted, partially melted, unmelted) that form the information code without creating hollow cavities. This parameter change allows the information code to be embedded while maintaining the structural integrity of the work piece.
Solution Approach 2:
The patent applies local quality by creating spatially varying microstructures within the same work piece. Different regions have different melting states (fully melted, partially melted, unmelted) that correspond to different information code states, allowing the information to be encoded through local microstructural variations rather than through hollow cavities.
2Loss of information
If additional materials are used to create identifiable structures during additive construction, then information codes can be formed, but the generating process becomes complex
Solution Approach 1:
The patent uses homogeneity by encoding information solely through variations in the microstructure of a single material system. The same raw material powder is used throughout, and information is stored through differences in melting state and microstructure rather than through the introduction of different materials, thereby simplifying the generating process.
Solution Approach 2:
The patent extracts the information encoding function from the material composition domain and relocates it to the processing parameter domain. Instead of using different materials to encode information, the invention extracts the information carrier role and assigns it to microstructural features created by controlled laser processing parameters.
3Loss of information
If post-processing steps are used to provide information codes on completed work pieces, then information can be added, but the production process becomes time consuming
Solution Approach 1:
The patent applies preliminary action by embedding the information code during the additive manufacturing process itself, before the work piece is completed. The information code is created as part of the layer-by-layer construction process through controlled undermelting in specific regions, eliminating the need for separate post-processing steps to add information codes.
Solution Approach 2:
The patent merges the information encoding function with the additive manufacturing process. The same laser system that builds the work piece also creates the information code by selectively controlling the melting state of powder in different regions, combining two functions (work piece generation and information encoding) into a single integrated 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
Enables the generation of stable three-dimensional work pieces with embedded information codes without additional materials, allowing for non-destructive optical reading and maintaining mechanical integrity.
Implementation Method 1
The laser radiation penetrating into the powder layer causes heating and consequently melting or sintering of the raw material powder particles
Implementation Method 2
Selective laser melting or selective laser sintering is an additive layering process, by which pulverulent, in particular, metallic and/or ceramic raw materials can be processed to three-dimensional work pieces of complex shapes
Implementation Method 3
a raw material powder layer is applied onto a carrier and subjected to laser radiation in a site-selective manner in dependence on the desired geometry of the work piece that is to be produced
Data Source
AI summary
A method and an apparatus (10) for generating a three-dimensional work piece containing an information code are provided. The method comprises the steps of applying a raw material powder (18) onto a carrier (14) by means of a powder application device (16), irradiating electromagnetic or particle radiation (22) onto the raw material powder (18) applied onto the carrier (14) by means of an irradiation device (20), and controlling the operation of the powder application device (16) and the irradiation device (20) so as to generate an information code pattern (36) on or in the work piece (12), wherein the information code pattern (36) is defined by the microstructure (34) of the work piece (12).