3D Print Engine Gas Flow Directors for Uniform Plume Removal
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Solution Overview
Problem
Existing 3D printing systems face challenges in fabricating large, defect-free articles due to plume clouds generated during the fusion of metal powders, which can obstruct energy beams and result in incomplete fusion, especially over large build planes, as previous gas flow control methods fail to provide uniform velocity vectors, leading to variable results.
Innovation Solution
A 3D print engine with a gas flow director structure that includes a peripheral plate with projecting structures such as fins and dams to shape the gas flow field, ensuring uniform gas flow velocities across the build plane, effectively removing plumes without disturbing metal powder particles, allowing for concurrent use of multiple energy beams over large areas like 0.5 to 1 square meter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If gas flow is increased to remove plume, then plume removal effectiveness improves, but powder particles are disturbed
Solution Approach 1:
The gas flow director structures create locally optimized flow conditions at different positions above the build plane. The structures include varying heights and configurations (such as fins and dams) that generate regions of different flow characteristics, allowing effective plume removal in some areas while maintaining gentle flow in other areas to avoid disturbing powder particles.
Solution Approach 2:
The gas flow director structures modify the gas flow velocity parameter across different spatial locations. By introducing structures with different geometries and positions, the system creates a non-uniform velocity distribution that optimizes plume removal effectiveness while preventing excessive disturbance to powder particles, thus resolving the contradiction between these two requirements.
2Productivity
If multiple energy beams are used concurrently, then productivity improves, but plume interference between beams increases
Solution Approach 1:
The gas flow director structures act as intermediary elements that manage the interaction between multiple energy beams and plumes. By controlling gas flow patterns, these structures create channels and regions that facilitate plume evacuation while minimizing cross-interference between adjacent beams, enabling concurrent operation of multiple beams without significant plume interference.
3Manufacturing precision
If uniform gas flow velocity is achieved, then plume removal consistency improves, but device complexity increases
Solution Approach 1:
The gas flow director structure is segmented into multiple discrete elements such as fins, dams, and other geometric features distributed across the build plane. Each segment contributes to the overall flow uniformity, and their collective arrangement creates the desired uniform velocity distribution without requiring a monolithic complex structure.
Solution Approach 2:
By strategically positioning gas flow director structures at specific locations and orientations, the system achieves uniform gas flow velocity across the build plane. The parameters of these structures (height, spacing, orientation) are optimized to generate consistent flow patterns, thereby achieving flow uniformity with controlled structural complexity.
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 solution enables the production of uniformly defect-free large 3D articles by maintaining consistent gas flow velocities, ensuring effective plume removal and minimizing interference between multiple energy beams, thereby enhancing the quality and size of fabricated products.
Implementation Method 1
a gas inlet that ejects a gas flow stream at an inlet end of the build chamber and passes over the build plane and at least part of the upper surface of the peripheral plate
Implementation Method 2
a beam system configured to generate a plurality of energy beams that scan over a build plane within the lateral area of the build plate and that is generally at a fixed height for powder fusion
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A three-dimensional (3D) print engine includes (A) a plurality of walls laterally defining a build chamber, (B) a build box including a build plate, (C) a powder dispenser, (D) a beam system for fusing layers of powder, (E) a peripheral plate disposed between the build plate and the plurality of walls and having an upper surface, (F) a gas inlet (54) that ejects a gas flow stream that passes over the build plate and the peripheral plate, (G) a gas outlet (56) that receives the gas flow stream, (H) a plurality of projecting structures (70, 72, 74, 76) mounted to and extending above the upper surface of the peripheral plate, and (I) a gas handling system coupled to the gas inlet and gas outlet. The plurality of projecting structures shape the flow field of the gas flow stream to provide a more uniform velocity of gas flow velocities above the build plane.