Additive Manufacturing Heating Device for Uniform Powder Bed Temperature
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Solution Overview
Problem
Existing additive manufacturing devices face challenges in achieving uniform temperature distribution over the powder surface, leading to temperature differences and unpredictable physical characteristics in the manufactured solid articles.
Innovation Solution
A device with a heating surface that is transparent to the laser beam and has independent temperature control, allowing for precise temperature maintenance across the powder surface, minimizing temperature variations to within +/-3 degrees Celsius.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a laser beam is used to selectively sinter powder layer-by-layer, then a solid article can be manufactured with complex geometry, but temperature distribution becomes non-uniform leading to warpage and unpredictable physical characteristics
Solution Approach 1:
The patent applies preliminary heating of the powder bed to a temperature close to the melting point of the powder material before laser sintering. This pre-heating action reduces the thermal gradient during laser processing, minimizing warpage and improving dimensional accuracy while maintaining the ability to manufacture complex geometries
Solution Approach 2:
The patent changes the temperature parameter by maintaining the powder bed at an elevated temperature (close to melting point) throughout the manufacturing process. This parameter change transforms the thermal conditions from cold-start sintering to hot-bed sintering, resulting in more uniform temperature distribution and reduced thermal stress
2Productivity
If the laser power is increased to improve sintering speed, then productivity increases, but thermal stress and warpage increase leading to reduced manufacturing precision
Solution Approach 1:
By pre-heating the powder bed before laser application, the system reduces the additional thermal stress caused by high-power laser sintering. This allows higher laser powers to be used for faster sintering while maintaining dimensional accuracy through reduced thermal gradients
3Temperature
If traditional heating devices are used to pre-heat the powder, then temperature control is improved, but the heating device blocks the laser beam path
Solution Approach 1:
The patent uses the powder bed itself as an intermediary medium that serves dual functions: it is heated by heating elements embedded in or near the powder container, and simultaneously allows laser beam penetration for sintering. This eliminates the need for separate heating devices that would block the laser path
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 solution ensures a uniform temperature distribution, improving the quality and predictability of the solid articles by reducing thermal stress and warpage, and eliminating the need for individual testing to meet specifications.
Implementation Method 1
a heating device for providing thermal energy to a raw material surface to form a pre-heated raw material surface
Implementation Method 2
a laser beam is directed onto the pre-heated raw material surface to sinter the pre-heated raw material surface
Data Source
AI summary
An additive manufacturing device for manufacturing a solid article comprises a laser generation unit, a raw material supply unit, a raw material container containing a raw material and having a raw material surface exposed to a laser beam to be emitted by the laser generation unit in operation and a control unit. The heating device includes a heating surface for heating the raw material surface to form a pre-heated raw material surface. The laser generation unit is disposed with a directing unit to direct the laser beam onto the pre-heated raw material surface according to a computer generated model of the solid article stored in a storage unit associated with the control unit. The laser beam generated by the laser generation unit passes through the heating surface onto the pre-heated raw material surface.