3D Additive Manufacturing Charge Shield for Unsintered Powder
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Solution Overview
Problem
Existing three-dimensional laminating and shaping techniques fail to effectively prevent charge-up of unsintered regions, leading to the scattering of metal powder particles and a smoke phenomenon due to insufficient calcination.
Innovation Solution
A three-dimensional laminating and shaping apparatus that employs a charge shield, which is grounded and moves to cover unsintered regions during electron beam irradiation, preventing charge accumulation and ensuring complete calcination of the metal powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electron beam irradiation is applied to sinter metal powder in three-dimensional laminating and shaping, then the three-dimensional object can be formed through melting and solidification, but charge-up occurs in the unsintered region causing metal powder particles to scatter and producing a smoke phenomenon
Solution Approach 1:
A charge shield is introduced as an intermediary component between the electron beam source and the unsintered metal powder. The charge shield, made of conductive material and grounded, intercepts scattered electrons before they reach the unsintered powder region, thereby preventing charge accumulation without interfering with the sintering process in the targeted area.
Solution Approach 2:
The shielding approach is segmented to cover only the unsintered regions while leaving the sintering area exposed to the electron beam. The charge shield is positioned and shaped to selectively protect specific zones, allowing the electron beam to continue its function in the sintering region while preventing charge-up in adjacent unsintered areas.
2Object-affected harmful factors
If a charge shield is introduced to prevent charge-up, then metal powder scattering and smoke phenomenon are eliminated, but the device complexity increases
Solution Approach 1:
The charge shield is implemented as a thin, flexible conductive plate that can be easily positioned and adjusted. This thin-film approach minimizes the added complexity while effectively performing the charge-shielding function, as the shield does not require substantial thickness or complex structural support.
Solution Approach 2:
The charge shield is grounded to utilize the existing ground connection in the apparatus, eliminating the need for a separate power supply or active control system. The shield passively intercepts scattered electrons through its grounded conductive surface, requiring no additional energy input or complex control mechanisms.
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
The charge shield effectively suppresses charge-up in unsintered regions, preventing the scattering of metal powder particles and the occurrence of a smoke phenomenon, ensuring reliable and precise shaping of three-dimensional objects.
Implementation Method 1
irradiates a material spread on a shaping surface by a recoater or the like with an electron beam, thereby melting the material, solidifying the material
Implementation Method 2
melting the material, solidifying the material
Implementation Method 3
calcination, thereby reliably preventing a smoke phenomenon
Implementation Method 4
charge shield, which is grounded and moves to cover unsintered regions during electron beam irradiation, preventing charge accumulation
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
This invention effectively prevents charge-up of an unsintered region. A three-dimensional laminating and shaping apparatus includes a linear funnel for recoating the material of a three-dimensional laminated and shaped object onto a shaping surface on which the three-dimensional laminated and shaped object is to be shaped. The three-dimensional laminating and shaping apparatus also includes an electron gun for generating an electron beam. The three-dimensional laminating and shaping apparatus further includes a charge shield for shielding the material recoated on the shaping surface when irradiating the material with the electron beam. In addition, the apparatus includes a vertical driving mechanism for vertically moving the charge shield.