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增材制造驅動創(chuàng)新設計

RenAM 500Q的主要驅動力 — 內(nèi)置創(chuàng)新型光學系統(tǒng)是雷尼紹各部門（控制部、軟件部和機械工程部）齊心協(xié)力為RenAM 500Q設計的關鍵組件。
摻鐿光纖激光束進入光學系統(tǒng)后，由通過精密振鏡底座驅動的四對掃描振鏡引導，掃描振鏡旋轉，引導激光束覆蓋在加工托盤的粉末上。光學系統(tǒng)也會動態(tài)聚焦激光，不斷調(diào)整焦距，確保光束角度在平坦的工作區(qū)域內(nèi)發(fā)生變化時光斑尺寸保持不變。要在粉末床上實現(xiàn)高精度加工，需借助專業(yè)的光學和控制工程技術；而這些技術經(jīng)過雷尼紹多年來在REVO（用于坐標測量機）等產(chǎn)品上不斷研發(fā)改進，已經(jīng)非常成熟。
雷尼紹利用自有增材制造 (AM) 技術生產(chǎn)出RenAM 500Q的光學系統(tǒng)。采用該技術一方面可使掃描振鏡的封裝更加嚴密，另一方面還可以設計出內(nèi)部隨形冷卻水道，確保光學系統(tǒng)具有精確的熱穩(wěn)定性。雷尼紹在制程中利用增材制造技術實現(xiàn)了上述創(chuàng)新，因此RenAM 500Q的加工效率大幅提升，解決了目前占市場主流的中型增材制造設備所面臨的瓶頸問題。
光學系統(tǒng)從構思到成品，離不開組合制造技術的使用；具體方法是將損耗性加工托盤作為成品部件的組成部分，這樣不僅可以減少耗材量，還可以減少從托盤上移除零件所需的加工步驟。位于斯塔福德郡的雷尼紹增材制造解決方案中心針對批量生產(chǎn)，對零件、增材制造支撐結構及制造設計進行了進一步優(yōu)化。
釋放生產(chǎn)力

新型四激光系統(tǒng)在不增大工作臺尺寸的情況下，可將生產(chǎn)效率提升3倍之多。大型增材制造設備通常會面臨較多問題，包括：材料庫存的增加、重型基板的機械裝卸、較大工作區(qū)域內(nèi)保護氣體的效率、資金成本的增加以及占地面積的增大等。要生產(chǎn)大型零件，必須消化這些不利因素，但就市場吸引力而言，中型設備更具優(yōu)勢。目前，中型設備面臨的主要阻礙是激光器數(shù)量有限而降低生產(chǎn)效率。
RenAM 500Q以雷尼紹RenAM 500M單激光系統(tǒng)的系統(tǒng)架構為基礎開發(fā)而成，兩者均可用于批量生產(chǎn)，但是存在一些明顯差異。最大的區(qū)別是RenAM 500Q有四個激光器，但是所有子系統(tǒng)都必須根據(jù)生產(chǎn)量的增加情況重新進行設計。此外，四個激光器在增材制造過程中對粉塵的處理能力也非常重要。如果通過提高氣體流通量和氣流速度來解決這一問題，會增加濾芯（用于收集粉塵）等其他子系統(tǒng)的作業(yè)負擔。因此，雷尼紹的做法是在氣流中裝設一個熱轉換器來保持加工溫度的穩(wěn)定性，同時利用預過濾旋風分離器來分離小顆粒與大顆粒粉末，從而延長濾芯壽命并提高粉末的循環(huán)利用率。
其他改進措施包括改善整個加工區(qū)域的氣流穩(wěn)定性，顯著減少流程間的清潔作業(yè)量。RenAM 500Q在整個加工區(qū)域設置有四個激光器，因此保持光學系統(tǒng)和粉末床之間的精確位置關系也至關重要。工程技術的進步有助于確保上述目標的實現(xiàn)，這些進步包括使用精密運動配件重新定位刷粉器、縮短設置時間以及提高重復精度等。
結構緊湊，潛力巨大

要高效使用四個激光器，需進行更多的前期規(guī)劃和工藝過程管理工作。最直接的切入點是讓每個激光器加工一個或一組獨立零件。如此一來，激光器便可并行作業(yè)。初步研究顯示，同時加工多個相鄰零件時需格外小心，因為加工一個零件排放的廢氣可能會影響另一個零件。結果表明，盡管加工出的零件表面光潔度存在一些細微差異，但總體而言，激光器并行作業(yè)是一種最容易管理的加工情形，也是推薦給大多數(shù)用戶使用的入門方法。
除此之外，在多激光加工過程中，選擇哪種加工方式主要取決于具體應用場合。顯然，可以使用四個激光器加工同一個零件，并且由于雷尼紹RenAM 500Q的每個激光器都能覆蓋整個金屬粉末床，用戶因而可以選擇最優(yōu)化的加工策略。
 

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