Additive Manufacturing Coater with Dynamic Vertical Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems face issues with material distribution, particularly with blade coaters hanging up on edges of solidified material, which can damage the blade and disrupt the coating process.
Innovation Solution
A system comprising a coating device with a base, coater, and drivetrain that includes beams with slots and actuators, allowing for controlled movement and compaction of material across the support surface, reducing the likelihood of the coater getting stuck on solidified material by using a belt and rollers to distribute and compact the material uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a blade coater is used to deposit powder material, then material distribution is achieved, but the blade hangs up on edges of solidified material causing damage
Solution Approach 1:
The coater is made movable in the vertical direction relative to the support surface, allowing it to adapt its position dynamically. This dynamic adjustment prevents the coater from hanging up on solidified material edges, resolving the contradiction between maintaining contact for uniform distribution and avoiding damage from hanging up.
Solution Approach 2:
A drivetrain system with beams, slots, and actuators is introduced as an intermediary mechanism between the coater and the support surface. This intermediary system enables controlled vertical movement and compaction, allowing the coater to navigate over solidified material edges without direct harmful contact, thus protecting the blade while maintaining material distribution capability.
2Productivity
If the coater contacts solidified material directly, then material is pushed across the surface, but the coater gets stuck and damages the blade
Solution Approach 1:
The coater's vertical position is made dynamic rather than fixed, allowing it to move up and down to clear solidified material edges. This prevents the coater from getting stuck and maintains continuous coating operation without blade damage.
Solution Approach 2:
The drivetrain system with actuators provides controlled movement capability before the coater encounters solidified material edges. This advance capability allows the coater to roll over or adjust to edges smoothly, preventing sudden hanging up and blade damage.
3Reliability
If the blade is elevated above the support surface, then the blade avoids contact with solidified material, but material distribution uniformity deteriorates
Solution Approach 1:
The coater's vertical position is dynamically adjustable through the drivetrain system. The coater can be elevated to avoid contact when needed, or lowered to maintain close proximity for uniform material distribution, resolving the contradiction between protection and precision.
Solution Approach 2:
The system uses the drivetrain actuators to automatically adjust the coater's position based on the terrain of solidified material. This self-adjusting capability allows the coater to maintain optimal positioning for material distribution while avoiding damage from excessive contact.
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 system ensures consistent and uniform material distribution, reducing the risk of blade damage and improving the additive manufacturing process by allowing the coater to rollover solidified material without hanging up, thereby enhancing the manufacturing efficiency and quality.
Implementation Method 1
The drivetrain is adapted to drive the coater to move across the support surface... the coater to rollover solidified material without hanging up
Implementation Method 2
The coater is adapted to compact the material to provide a layer of the material... compact the material to provide a layer of the material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A process is provided for additively manufacturing at least one part. The processing includes depositing a substantially uniform layer of material over at least a portion of a support surface using a belt that contacts the material. The process also includes solidifying at least a portion of the layer of material using a solidification device to form at least a portion of the part.