University of Pittsburgh engineers have developed an innovative algorithm designed to optimize the scanning patterns in laser powder bed fusion additive manufacturing. This novel approach aims to significantly reduce residual stress and deformation in manufactured parts by enhancing the laser scanning direction through the finite element analysis of part-scale residual deformation.
Description
The new scanning pattern optimization algorithm provides a major advancement in additive manufacturing technology by focusing on minimizing residual deformation. This is achieved by modifying the laser scanning directions of islands within the scanning strategy, which is based on layer-wise sensitivity analysis and the inherent strain method. The optimized scanning pattern can reduce residual deformation by up to 40%, offering substantial improvements over traditional scanning strategies.
Applications
Aerospace
Medical Devices
Automotive
Advantages
The scanning pattern optimization algorithm offers several key advantages over traditional scanning strategies. Firstly, it reduces residual stress and deformation by up to 40%, which significantly enhances the mechanical properties and dimensional accuracy of printed parts. This reduction in deformation leads to fewer defects and lower rejection rates, ultimately decreasing production costs and time. Additionally, by minimizing the need for extensive post-processing, this technology allows manufacturers to streamline their workflows and improve overall productivity. The ability to integrate the algorithm into existing pre-processing software also ensures easy adoption and compatibility with commercial and open-architecture LPBF systems, making it a versatile and scalable solution for various applications in metal additive manufacturing.
Invention Readiness
The development of this technology has progressed to the concept stage, supported by computational simulations that demonstrate its effectiveness in reducing residual stress and deformation. The algorithm has been tested using finite element analysis, which validated its ability to optimize scanning patterns based on the unique geometry of parts being produced. The technology is now being prepared for further refinement and testing, with plans to integrate it into commercial LPBF systems for real-world applications. Ongoing developments include expanding the algorithm's capabilities to accommodate a wider range of materials and part geometries, ensuring broad applicability across different manufacturing sectors.
IP Status
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