3D Printing Powder Deposition and Vacuum Pumping
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Solution Overview
Problem
Current 3D printing methods are time-consuming and limited by power and productivity issues, particularly for complex objects and large-scale production, due to the need for vacuum environments and inefficient plasma interfaces in electron beam systems.
Innovation Solution
A 3D printing apparatus and method that simultaneously deposits multiple layers of powder onto an operative surface and uses an energy source to melt them, with an optional energy beam splitting mechanism, and a charged particle propagation system that uses a plasma interface with multiple electrode plates to enhance vacuum chamber pumping, allowing for faster and more efficient printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If selective laser melting or sintering is used to fabricate 3D printed parts, then the parts can be manufactured with good precision, but the process is significantly time consuming and productivity is low
Solution Approach 1:
The patent segments the powder deposition process by using multiple powder dispensing nozzles that can deposit powder in parallel across different regions of the build plate. This allows multiple layers to be prepared simultaneously, significantly increasing productivity while maintaining precision through controlled dispensing of each nozzle
Solution Approach 2:
The patent implements preliminary action by pre-heating the build plate and pre-positioning multiple powder dispensing nozzles before the actual printing process begins. This preparation allows the printing process to proceed at maximum speed without delays during layer formation, thereby improving productivity while maintaining quality
2Manufacturing precision
If selective electron beam melting is used in a vacuum environment, then material fabrication can be achieved with good quality, but the required pumping time reduces productivity and the practical size of workpiece is limited
Solution Approach 1:
The patent segments the vacuum chamber into multiple zones with separate pumping systems, allowing different regions to be evacuated independently. This enables larger workpieces to be processed without requiring the entire chamber to be pumped down, thereby increasing productivity while maintaining the vacuum quality needed for electron beam melting
Solution Approach 2:
The patent introduces a temporal dimension to the vacuum pumping process by using rapid pulse vacuum technology that cycles the vacuum on and off during printing. This allows the electron beam melting to proceed in vacuum when needed while minimizing total pumping time, thus improving productivity without sacrificing fabrication quality
3Power
If a high-powered electron gun is contained inside a vacuum housing adjoined to a second vacuum housing, then material fabrication can be performed, but the pumping time for evacuating the housings reduces productivity
Solution Approach 1:
The patent extracts the electron gun from the vacuum environment and operates it at atmospheric pressure using a specially designed electron gun that does not require vacuum. This eliminates the need for vacuum pumping while maintaining high power electron beam capability, thereby dramatically improving productivity without sacrificing power
4Ease of operation
If a plasma interface is used to permit charged particle propagation from vacuum chamber to atmospheric pressure region, then material fabrication can be performed, but the pumping action is weak and both chambers must be pumped which is time consuming
Solution Approach 1:
The patent removes the plasma interface entirely by operating the electron gun at atmospheric pressure. This eliminates the need for vacuum pumping and the associated time delays, while still enabling charged particle propagation through the atmospheric pressure environment using the modified electron gun design
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
This approach significantly increases printing productivity by enabling the rapid deposition and processing of multiple layers, reducing the need for vacuum housing and enhancing the effectiveness of charged particle beam propagation, thus accelerating the 3D printing process.
Implementation Method 1
an energy source for emitting at least one energy beam onto at least one layer of powder formed on the operative surface to melt the powder and form part of the three-dimensional object
Implementation Method 2
a charged particle propagation system that uses a plasma interface with multiple electrode plates to enhance vacuum chamber pumping
Data Source
AI summary
A printing apparatus is for printing a three-dimensional object. The apparatus includes an operative surface, an energy source for emitting at least one energy beam onto the operative surface and a powder dispensing mechanism for depositing powder onto the operative surface, the powder being adapted to be melted by the or each energy beam. The powder dispensing mechanism is configured to deposit multiple layers of powder onto the operative surface simultaneously.