Additive Manufacturing Coater with Integrated Extraction and Heating

Solution Overview

Problem

Existing additive manufacturing devices for components, particularly turbomachines, face inefficiencies in removing smoke, splashes, and process exhaust gases, often requiring high equipment costs.

Innovation Solution

A device with a coater and a movable extraction and/or gas supply system integrated to the coater, allowing for effective removal of smoke, splashes, and process exhaust gases during the manufacturing process, while also incorporating a movable heating device for consistent temperature control to prevent hot cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional additive manufacturing devices are used, then component manufacturing is achieved, but smoke, splashes, and process exhaust gases are not effectively removed requiring high equipment costs

Engineering Contradiction:

Improveremoval of smoke, splashes, and process exhaust gasesVSAvoidequipment cost

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The extraction and gas supply devices are mechanically coupled to the coater, combining two separate functional systems into one integrated unit. This merging allows the coater's movement to simultaneously position both the coating application and the extraction/gas supply functions, eliminating the need for separate extraction device mounting structures and reducing overall equipment complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coater is transformed into a multi-functional carrier that performs both its primary function of applying powder material and the additional function of supporting extraction and gas supply devices. This universality allows a single moving component to serve multiple purposes in the additive manufacturing process, reducing the total number of independent systems required.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If extraction and gas supply devices are added to additive manufacturing devices, then harmful factors are effectively removed, but device complexity increases

Engineering Contradiction:

Improveremoval of smoke, splashes, and process exhaust gasesVSAvoiddevice structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The extraction and gas supply devices are mechanically coupled to the coater, combining two separate functional systems into one integrated unit. This merging allows the coater's movement to simultaneously position both the coating application and the extraction/gas supply functions, eliminating the need for separate extraction device mounting structures and reducing overall equipment complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coater is transformed into a multi-functional carrier that performs both its primary function of applying powder material and the additional function of supporting extraction and gas supply devices. This universality allows a single moving component to serve multiple purposes in the additive manufacturing process, reducing the total number of independent systems required.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If heating device is added to prevent hot cracking, then component reliability is improved, but device complexity increases

Engineering Contradiction:

Improveprevention of hot crackingVSAvoiddevice structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating device is integrated with the coater assembly, combining thermal processing functionality with the material application system. This integration allows the coater to simultaneously perform powder application and controlled heating, eliminating the need for a completely separate heating system and reducing overall device complexity while improving reliability through consistent temperature control.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables reliable and cost-effective removal of manufacturing by-products and ensures consistent temperature control, preventing hot cracking, particularly with high-temperature alloys, thus improving the manufacturing process efficiency.

Implementation Method 1

at least one coater (14) for applying at least one powder layer (38) of a component material to at least one build-up and joining zone (20)

Methodology Applied

Scientific EffectPowder coating: Deposition (physical)

Implementation Method 2

at least one radiation source (22) for generating at least one high-energy beam by means of which the powder layer (38) in the region of the build-up and joining zone (20) can be locally melted and/or sintered

Methodology Applied

Scientific EffectLaser beam melting: Laser

Implementation Method 3

at least one radiation source (22) for generating at least one high-energy beam by means of which the powder layer (38) in the region of the build-up and joining zone (20) can be locally melted and/or sintered

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Implementation Method 4

at least one extraction and/or gas supply device (36) for removing smoke, splashes and/or process exhaust gases from the additive manufacturing process from the build-up and joining zone (20)

Methodology Applied

Scientific EffectGas extraction: Suction

Implementation Method 5

at least one heating device for heating the component material is arranged on the coater (14) in a movable or non-movable manner at least in the region of the build-up and joining zone (20)

Methodology Applied

Scientific EffectInductive heating: Induction Heating

Data Source

PatentEP3010672B1Device and method for the additive manufacturing of at least one component region of a component

Publication Date: 2025.10.01 EOS GMBH ELECTRO OPTICAL SYST

Figure 1
Figure 2~3

AI summary

The invention relates to a device (10) for additively producing at least one component region of a component (12), in particular a component (12) of a turbomachine. The device (10) can comprise at least one component platform (16), which can be lowered and which has at least one constructing and joining zone (20) for accommodating at least one powder layer of a component material, at least one heating device (24, 28) that can be moved in relation to the component platform (16), and at least one radiation source for producing at least one high-energy beam (22), by means of which high-energy beam the powder layer can be locally fused and/or sintered to form a component layer in the region of the constructing and joining zone (20), and at least one suctioning and/or gas-feeding device (36), which is arranged on the heating device (24, 28). The device (10) can, however, also comprise at least one coating apparatus (14) for applying at least one powder layer of a component material to at least one constructing and joining zone (20) of at least one component platform (16) that can be lowered, wherein the coating apparatus (14) can be moved in relation to the component platform (16), and at least one suctioning and/or gas-feeding device (36), which is arranged on the coating apparatus (14).