Additive Manufacturing Gas Removal Flow Control

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Solution Overview

Problem

Existing devices for additive manufacturing of three-dimensional objects using energy beams for selective hardening of building material layers face inefficiencies in the removal of process gases, particularly smoke and fumes, due to limitations in fluid flow generation and gas discharge mechanisms.

Innovation Solution

The device incorporates a flow device for generating a fluid flow through the process chamber, equipped with a diffuser element for creating a laminar flow profile, a detection system for monitoring physical and chemical parameters of the fluid flow, and a control mechanism to adjust the flow parameters and suction operations based on real-time data for enhanced gas removal efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a conventional flow device is used to remove process gases, then gas removal is achieved, but the gas removal efficiency is insufficient and cannot adapt to varying process conditions

Engineering Contradiction:

Improvegas removal efficiencyVSAvoidadaptability to varying process conditions

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The flow device is designed with adjustable flow rates and multiple operational modes, allowing dynamic adaptation to varying process conditions during additive manufacturing. The system can modify fluid flow characteristics in real-time to optimize gas removal efficiency for different manufacturing scenarios.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Sensors monitor process gas concentration and flow conditions, providing feedback to the control system. This enables automatic adjustment of the flow device parameters to maintain optimal gas removal efficiency under changing process conditions, transforming a static system into an adaptive one.

Inventive Principle:

Principle #23Feedback

2Productivity

If the fluid flow is increased to improve gas removal, then gas discharge efficiency improves, but energy consumption increases

Engineering Contradiction:

Improvegas discharge efficiencyVSAvoidenergy consumption of flow device

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system optimizes fluid flow parameters (velocity, pressure, distribution pattern) to achieve maximum gas removal efficiency at minimum energy consumption. By carefully tuning these parameters rather than simply maximizing flow rate, the system achieves high productivity without proportional energy increases.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of uniformly high flow throughout the chamber, the system applies fluid flow locally where process gases are most concentrated. This targeted approach removes gases efficiently while minimizing overall energy consumption by avoiding unnecessary high-flow regions.

Inventive Principle:

Principle #3Local quality

3Productivity

If a simple flow device is used, then device complexity is low, but gas removal efficiency is insufficient

Engineering Contradiction:

Improvegas removal efficiencyVSAvoidcomplexity of flow device

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The flow device is divided into multiple independent flow outlets or zones, each capable of independent control. This segmentation allows the system to achieve high gas removal efficiency through distributed flow management while maintaining modular simplicity, where each segment can be optimized independently.

Inventive Principle:

Principle #1Segmentation

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 setup allows for improved quantitative and qualitative assessment and adjustment of gas removal processes, ensuring efficient discharge of process gases and maintaining a controlled environment within the manufacturing chamber, thereby enhancing the additive manufacturing process.

Implementation Method 1

a flow device for generating a fluid flow that at least partially passes through a process chamber of the device... Fluid flows generated by such flow devices serve in particular to remove process gases

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

a detection unit configured to acquire flow information specifying or describing at least one physical parameter and/or at least one chemical parameter of the fluid flow

Methodology Applied

Scientific EffectGas detection:

Implementation Method 3

The device incorporates a flow device for generating a fluid flow through the process chamber, equipped with a diffuser element for creating a laminar flow profile

Methodology Applied

Scientific EffectLaminar flow: Laminar Flow

Data Source

PatentEP3871858B1Device and process for generative manufacture of at least one three-dimensional object

Publication Date: 2023.07.19 CONCEPT LASER

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AI summary

Device (1) for the additive manufacturing of a three-dimensional object (2).