Additive Manufacturing Fill-Level Sensing With Gas-Pressure Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing measurement techniques for determining the fill level of collection containers in additive manufacturing apparatuses, such as weighing and optical sensors, introduce additional components and require frequent cleaning, and are limited by field of view, making them impractical for accurate and contactless measurement.

Innovation Solution

A fill level sensor using the ideal gas law to calculate the volume of particulates or build material in a collection container by measuring pressure change and temperature, allowing for contactless determination of fill levels without contamination and easy integration into existing systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If weighing scales are used to measure fill level, then measurement can be obtained, but additional components are introduced and cleaning is required frequently

Engineering Contradiction:

Improvefill level measurementVSAvoidadditional components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces mechanical weighing scales with an optical measurement system. The optical sensor detects fill level by measuring light transmission or reflection properties of the powder bed, eliminating the need for mechanical contact and associated cleaning requirements while maintaining measurement capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces optical light as an intermediary medium to transfer information about fill level without direct mechanical contact. The light interacts with the powder bed and carries measurement information back to the sensor, serving as a non-contact mediator between the measurement system and the material.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If optical sensors are used to measure fill level, then measurement is obtained, but field of view is limited

Engineering Contradiction:

Improvefill level measurementVSAvoidfield of view

Core Design Contradiction:

Measurement precisionVSArea of stationary object

Solution Approach 1:

The patent transitions from two-dimensional optical sensor measurements to three-dimensional fill level assessment by incorporating depth information through multiple measurement points or stereo imaging. This allows comprehensive coverage of the collection container volume while maintaining optical measurement advantages.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent divides the collection container into multiple measurement zones or segments, with optical sensors positioned to cover different regions. By combining data from multiple segmented measurements, the system achieves complete field of view coverage while using standard optical sensor components.

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If contact sensors are used to measure fill level, then measurement is obtained, but contamination risk increases

Engineering Contradiction:

Improvefill level measurementVSAvoidcontamination

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces contact-based mechanical sensors with non-contact optical sensing. The optical measurement system detects powder bed characteristics through light interaction without physical contact, completely eliminating the contamination risk associated with mechanical sensors that must touch the material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses light as an intermediary that can probe the powder bed without contamination. The optical field serves as a clean intermediary medium that transfers measurement information without direct material contact, preventing both sensor contamination and material degradation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 accurate and contactless measurement of fill levels in collection containers, reducing contamination risk and simplifying maintenance, while being compatible with various materials and processes.

Implementation Method 1

a fill level sensor fluidly connected to the collection container that detects a pressure change from displacement of an inert gas by the particulates received in the collection container

Methodology Applied

Scientific EffectPressure change from gas displacement: Pressure Gradient

Data Source

PatentEP4621359A1Fill level sensing devices and additive manufacturing apparatuses including same

Publication Date: 2025.09.24 CONCEPT LASER

Figure 1
Figure 2~3
Figure 4

AI summary

Disclosed herein are particulate (112') separation systems including a filter device (102) that separates particulates (112) from a particulate (112')-laden stream generated by an additive manufacturing apparatus (10). A collection container (120) is also included which is fluidly connected to the filter device (102) and receives the particulates (112) separated from the particulate (112')-laden stream. A fill level sensor (130) is further included which is fluidly connected to the collection container (120) and detects a pressure change from displacement of an inert gas by the particulates (112) received in the collection container (120).