3D Shaping Suction Inlet for Powder Suspension Control
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Solution Overview
Problem
Conventional three-dimensional shaping apparatuses face issues with powder suspension in air leading to defective ejection and contamination due to powder dispersion during the recoating process, causing problems like clogging and contamination within the apparatus.
Innovation Solution
A three-dimensional shaping apparatus is designed with a suction mechanism and a recoater system that includes a suction inlet positioned near the recoater roller's stop position to collect suspended powder, preventing it from clinging to the carriage or print head and reducing contamination by removing the powder from the air stream.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If powder is spread evenly with a recoater roller during feeding, then the powder layer is flattened and shaped layers are formed, but powder becomes suspended in air and clings to the carriage or print head causing defective ejection
Solution Approach 1:
The suction mechanism extracts suspended powder from the air stream near the shaping chamber. By positioning the suction inlet close to the second position where powder suspension occurs, the system removes harmful suspended particles before they can cling to the carriage or print head, thus maintaining ejection reliability while preserving the recoating function.
Solution Approach 2:
The suction mechanism acts as an intermediary element between the powder spreading process and the shaping process. It intercepts suspended powder particles in the air stream and removes them, preventing direct contact between the powder and the carriage/print head, thereby resolving the contradiction between maintaining powder layer quality and preventing ejection defects.
2Productivity
If powder is fed from feeding chamber to shaping chamber during recoating, then powder is supplied for shaping, but apparatus interior becomes contaminated by dispersed powder
Solution Approach 1:
The suction mechanism extracts dispersed powder from the air stream within the shaping chamber. By positioning the suction inlet close to the second position, it removes contaminated air and suspended powder particles before they can settle and contaminate the apparatus interior, thus maintaining high shaping speed while reducing contamination.
Solution Approach 2:
The suction mechanism converts the harmful effect of dispersed powder (contamination) into a controllable process. By actively removing suspended particles and directing them away from the apparatus interior, the system transforms the potentially harmful powder dispersion into a managed flow that can be extracted and disposed of, maintaining productivity while eliminating contamination.
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 configuration significantly reduces defective ejections and contamination, ensuring stable and efficient manufacturing of 3D shaped objects by minimizing powder dispersion and clogging issues.
Implementation Method 1
The suction mechanism includes a suction inlet arranged close to the second position
Data Source
AI summary
A three-dimensional shaping apparatus includes: a shaping chamber configured to hold powder; a leveler configured to move from a first position to a second position in a first direction on a top surface of the powder held in the shaping chamber to flatten the top surface of the powder; an ejector configured to eject a shaping liquid to the flattened top surface of the powder held in the shaping chamber; and a suction mechanism including a suction inlet arranged close to the second position of the shaping chamber.