DESC:[0003] The present invention discloses a system for computing scan strategy for enhancing quality of parts produced using Additive Layer Manufacturing. The invention particularly relates to a system for eliminating the interaction between the laser beam with the fumes emitted during an additive manufacturing process thereby enhancing the quality of parts.
Background of the invention
[0004] Additive manufacturing is a manufacturing process in which the required shape of a part or product is realized by adding material layer by layer to obtain the resultant shape as required. The adoption of additive manufacturing process for mainstream manufacturing is currently limited due to the challenges associated with the printing process such as, spatter generating from the melt pool, vapor produced during the melting process which may obstruct the irradiating medium and result in power losses, thermal drift, laser penetration and so on. In the current state of the art, the position of the laser source is fixed, wherein if the laser beam interacts with the fumes that is produced during the additive manufacturing process, the quality of the resultant parts is greatly compromised. Presently, there is no mechanism to eliminate the possibility of interaction between the laser beam and the fumes that is produced during the additive manufacturing process.
[0005] The Patent No. US10343216B2 titled “Method and device for producing a three-dimensional object” discloses a method for producing a three-dimensional object by applying layers of a pulverulent construction material and by selectively solidifying said material by the action of energy comprises the steps: a layer of the pulverulent construction material is applied to a support or to a layer of the construction material that has been previously applied and at least selectively solidified; an energy beam from an energy source sweeps over points on the applied layer corresponding to a cross-section of the object to be produced in order to selectively solidify the pulverulent construction material; and a gas flow is guided in a main flow direction over the applied layer during the sweep of the energy beam. The main flow direction (RG) of the gas flow (G) and the sweep direction (RL) of the energy beam are adapted to one another at least in one region of the cross-section to be solidified.
[0006] The Patent No. US20170173737A1 titled “Additive manufacturing method using a plurality of synchronized laser beams” discloses 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.
[0007] The Patent No. JP6609256B2 titled “Additive modeling apparatus and method for calibrating a laser scanner in an additive manufacturing apparatus” discloses a system provided for calibrating a laser scanning system in an additive manufacturing environment. The system may include a calibration plate with reference markings. The calibration plate may be arranged substantially parallel to the scanning area of the laser scanning system. The system may further include a laser scanner configured to emit a laser beam to a predefined location on the calibration plate. The laser beam forms a laser marking on the calibration plate. An image acquisition unit including an image acquisition device may be provided. The image acquisition device may be configured to image at least a portion of the calibration plate in relation to a predefined position on the calibration plate.
[0008] Hence, there exists a need for a system to reduce or eliminate the interaction between a laser beam and the fumes that are produced during the additive manufacturing process.
Summary of the invention
[0009] The present invention overcomes the drawbacks of the prior art by disclosing a system for computing a scan strategy for enhancing quality of parts produced using Additive Layer Manufacturing. The system comprises a scanner system for emitting a beam of laser light in a pre-defined direction. Further, the system comprises a base plate configured to receive a laser beam from the scanner system at a particular angle of incidence, wherein a solid angle is created between the plurality of laser beams with reference to the base plate. Furthermore, the system comprises a controller electrically connected to the base plate preprogrammed for facilitating the movement of the scanner system in a predefined direction.
[0010] The present invention provides a system for enhancing the quality of a part manufactured in an additive manufacturing. Additive manufacturing systems use the additive manufacturing processes to create three-dimensional components from digital models of the 3D parts. The extrusion-based techniques, ink jetting, selective laser sintering, powder/binder jetting, electron-beam melting, and stereolithographic processes are examples of commercially accessible additive manufacturing techniques.
Brief description of the drawings:
[0011] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.
[0012] FIG 1 illustrates a representation of the system for computing scan strategy for enhancing quality of parts produced using Additive Layer Manufacturing.
Detailed description of the invention:
[0013] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in the figures. Each example is provided to explain the subject matter and not a limitation. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope and contemplation of the invention.
[0014] The present invention discloses a system comprising a scanner system for emitting the laser beams. The system comprises a base plate over which the laser beam is incident, wherein the angle of incidence of the laser beam is monitored as the position of the scanner system shifts in a pre-defined direction which is pre-programmed using a controller. The solid angle created by a hatch line is considered to check for interaction between the laser beam and fumes generated during additive manufacturing process. If interaction is detected, the direction of the hatch line is reversed to create a positive solid angle which eliminates the possibility of interaction between the laser beam and the fumes generated during additive manufacturing process thereby resulting in good quality parts.
[0015] FIG 1 illustrates a representation of the system for computing scan strategy for enhancing quality of parts produced using Additive Layer Manufacturing. The system (100) comprises a scanner system (101) for emitting the beam of laser light in a pre-defined direction. In one embodiment, the position of the scanner system (101) is varied based on the operator’s requirement. The laser beam emitted by the scanner system (101) is incident on a base plate (102) at a particular angle of incidence. Further, the position of the scanner system (101) is through a controller (103) which is pre-programmed to facilitate the movement of the scanner system (101) in a pre-defined direction. The distance between two consecutive points of incidences is called a hatch line (104), wherein the angle formed between the plurality of laser beams with reference to the base plate (102) is a solid angle. In FIG 1,
Solid angle, ? = ?1 + ?2
[0016] If the solid angle, ? is a negative solid angle, it indicates the interaction between the laser beam and the fumes generated during the additive manufacturing process. In such cases, the direction including the end points of the hatch line (104) are reversed, which converts the negative solid angle to positive solid angle. In one embodiment, the action of reversing the direction of the hatch line (104) to convert a negative solid angle to a positive solid angle may be performed by the controller (103). A positive solid angle eliminates the possibility of interaction between the laser beam and the fumes generated during the additive manufacturing process which allows for improving the quality of parts which are produced through the process of additive layer manufacturing.
[0017] The present invention provides a solution to the problem of interaction between the laser beam and the fumes generated during the process of additive manufacturing. In case of such interaction, the system (100) converts the negative solid angle into positive solid angle by reversing the direction of the hatch line (104) thereby ensuring that the laser beam does not interact with the fumes. This elimination of the possibility of interaction by the system (100) ensures the production of good quality parts using the additive layer manufacturing process.

Reference numbers:
Components Reference Numbers
System 100
Scanner system 101
Base plate 102
Controller 103
Hatch line 104

,CLAIMS:We claim:
1. A system for computing scan strategy for enhancing quality of one or more parts produced using an Additive Layer Manufacturing process, the system (100) comprises:
a) a scanner system (101) for emitting at least one beam of laser light in a pre-defined direction;
b) a base plate (102) configured to receive the laser beam from the scanner system (101) at a particular angle of incidence; and
c) a controller (103) electrically connected to the base plate (102) preprogrammed for facilitating the movement of the scanner system (101) in a predefined direction.

2. The system (100) as claimed in claim 1, wherein a solid angle is created between the plurality of laser beams with reference to the base plate (102) for evaluating the interaction of the laser beam with the fumes produced during the additive manufacturing process.

3. The system (100) as claimed in claim 1, wherein a negative solid angle formed between the plurality of laser beams with reference to the base plate (102) is converted to a positive solid angle by the controller (103).

4. The system (100) as claimed in claim 1, wherein the controller (103) executes the action of reversing the direction of a hatch line (104) to convert the negative solid angle to positive solid angle.

5. The system (100) as claimed in claim 1, wherein the negative solid angle indicates the interaction between the laser beam and the fumes generated during the additive manufacturing process.

6. The system (100) as claimed in claim 1, wherein the positive solid angle eliminates the possibility of interaction between the laser beam and the fumes generated during the additive manufacturing process.