Adaptive Recoater Blade Spring Deflection for 3D Printing
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Solution Overview
Problem
In powder bed based additive manufacturing, existing application units can damage fragile parts of the object and contaminate the build material due to the use of materials like carbon brushes or rubber profiles, and rigid tools can apply excessive pressure, leading to object damage.
Innovation Solution
An application unit with a deflection unit that couples the application element to the carrier via a spring element, allowing relative movement to avoid excessive force on the object and reduce wear, using a rigid material like steel to minimize contamination and extend tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If rigid tools like steel tools are used as application elements, then tool life is extended and wear is reduced, but excessive pressure is applied to protruding regions of the object causing damage to filigree portions
Solution Approach 1:
The application element is made dynamically adaptable through a spring element connection to the application element carrier, allowing it to adjust its position and applied pressure dynamically. This resolves the contradiction by enabling the rigid steel application element to maintain its durability while automatically reducing pressure on protruding or filigree regions of the object, preventing damage through dynamic pressure adjustment.
2Object-affected harmful factors
If flexible materials like rubber profiles or carbon brushes are used as application elements, then pressure on the object is reduced, but fragments or complete bristles are removed during the application process contaminating the build material
Solution Approach 1:
The invention changes the material parameter of the application element from flexible materials (rubber, carbon) to rigid steel material, while simultaneously introducing a spring element to control the force parameter. This resolves the contradiction by eliminating contamination from material degradation while maintaining appropriate pressure through the spring's mechanical compliance, allowing the rigid steel element to function without shedding particles.
3Device complexity
If the application element is fixedly mounted on the application element carrier, then structural simplicity is maintained, but the application element cannot adapt to irregularities in the build plane or protruding objects leading to damage
Solution Approach 1:
The spring element serves as an intermediary component between the application element carrier and the application element. This mediator absorbs the complexity of providing adaptive pressure control while maintaining a relatively simple overall structure. The spring element enables the application element to adapt to build plane irregularities and protruding objects without requiring complex active control systems, resolving the contradiction between structural simplicity and adaptive capability.
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 prevents damage to filigree parts and reduces contamination, allowing the use of rigid materials with increased tool life and precise application of build material by deflecting the application element relative to the carrier, thus avoiding excessive forces and foreign particle contamination.
Implementation Method 1
The deflection unit (9) is adapted to enable a deflection of the application element (5) relative to the application element carrier (6)... the spring element may be compressed, wherein the application element is moved relative to the application element carrier
Data Source
Figure 1
Figure 2~3
AI summary
Application unit (1) for applying, in particular powdery, build material in a build plane (2) in a process chamber (3) of an apparatus (4) for additively manufacturing three-dimensional objects, which application unit (1) comprises an application element (5) carried by an application element carrier (6), characterized in that the application element (5) is coupled to the application element carrier (6) via at least one deflection unit (9).