Additive Manufacturing Chambers for Parallel Printing and Airlock Transfer
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Solution Overview
Problem
Traditional additive manufacturing systems face limitations in efficiency and throughput, particularly in powder bed fusion systems that operate in batch-mode, requiring substantial time to move parts between processing chambers for further work.
Innovation Solution
The system employs a high-throughput additive manufacturing method using a patterned energy beam to create parts weighing over 2,000 kilograms, with a gas management system maintaining low oxygen levels and an airlock for part transport, combined with energy patterning units and image relays to efficiently direct and reuse energy beams, and multiple chambers for concurrent printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-mode printing is used in traditional additive manufacturing systems, then manufacturing simplicity is maintained, but productivity and throughput are limited due to substantial time required to move parts between processing chambers
Solution Approach 1:
The system divides the manufacturing process into separate functional chambers (printing chamber, cooling chamber, heat treatment chamber) that operate in parallel. Each chamber performs a specific function, allowing simultaneous execution of different manufacturing steps for multiple parts, thereby increasing throughput without proportionally increasing overall system complexity
Solution Approach 2:
The system transitions from sequential batch processing to parallel processing by adding a spatial dimension with multiple chambers. Parts can be distributed across different chambers simultaneously, enabling concurrent manufacturing operations and significantly improving productivity beyond what a single chamber could achieve
2Use of energy by moving object
If energy beams are directed to all areas of the powder bed, then uniform processing is achieved, but energy efficiency decreases due to unused energy in non-print areas
Solution Approach 1:
The system applies energy selectively only to the specific areas of the powder bed where material deposition is required, rather than uniformly across the entire bed. This localized energy application improves energy efficiency while maintaining print quality through precise control of the energy beam targeting
Solution Approach 2:
The system captures and recycles unused inert gas that flows through the powder bed, redirecting it back into the system for reuse. This reduces energy waste associated with continuous gas generation and improves overall energy efficiency without affecting manufacturing precision
3Manufacturing precision
If atmospheric oxygen levels are present in the printing chamber, then equipment simplicity is maintained, but part quality deteriorates due to oxidation of metal powder
Solution Approach 1:
The system maintains an inert atmosphere (nitrogen or other inert gas) in the printing chamber to prevent oxidation of metal powder during the additive manufacturing process. This controlled environment ensures high part quality by eliminating oxidative reactions, despite the increased complexity of gas management systems required to maintain it
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 enhances manufacturing efficiency by allowing continuous part production and recycling of unused energy, reducing time and improving energy utilization, while enabling the creation of large and complex parts in a controlled environment.
Implementation Method 1
using a patterned energy beam to create parts
Implementation Method 2
powder bed fusion additive manufacturing
Implementation Method 3
gas management system maintaining low oxygen levels
Data Source
AI summary
A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock.