Additive Manufacturing Gas Flow Segmentation for Contamination Control
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Solution Overview
Problem
Current additive manufacturing devices face inefficiencies in removing process-related particulate contamination from the process chamber, which can affect the quality of three-dimensional objects produced.
Innovation Solution
A device with a flow device that generates an inert gas flow through the process chamber, divided into multiple partial gas flows with varying flow properties, ensuring complete coverage over the chamber height and minimizing turbulence for enhanced contamination removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single gas flow is generated through the process chamber, then the structure is simple, but the removal efficiency of particulate contamination is insufficient
Solution Approach 1:
The gas flow is divided into multiple partial gas flows (first partial gas flow and second partial gas flow) that flow through different regions of the process chamber. The first partial gas flow flows along the lower region and removes contaminants from the lower area, while the second partial gas flow flows along the upper region and removes contaminants from the upper area, including near the energy beam coupling device. This segmentation increases contamination removal efficiency without requiring a completely complex new structure.
Solution Approach 2:
Different regions of the process chamber are provided with gas flows having different properties tailored to local contamination patterns. The lower region receives a first partial gas flow optimized for removing contaminants generated during additive manufacturing, while the upper region receives a second partial gas flow optimized for removing contaminants near the energy beam coupling device. This local optimization enhances overall removal efficiency.
2Productivity
If gas flow velocity is increased to improve contamination removal, then removal efficiency increases, but turbulence increases and interferes with the energy beam
Solution Approach 1:
The gas flow system is segmented into multiple partial flows with different velocity characteristics. The first partial gas flow in the lower region can operate at higher velocities to effectively remove contaminants from the building area, while the second partial gas flow in the upper region operates at lower velocities to avoid interfering with the energy beam coupling device, thus resolving the conflict between removal efficiency and beam interference.
Solution Approach 2:
Different velocity characteristics are applied locally to different regions of the process chamber. The lower region experiences higher gas flow velocities optimized for contaminant removal, while the upper region experiences lower velocities optimized for minimizing energy beam interference. This local differentiation allows each region to operate under optimal conditions without compromising the other.
3Object-affected harmful factors
If the process chamber is frequently opened to remove contaminants, then contamination levels are reduced, but manufacturing precision deteriorates due to exposure to ambient environment
Solution Approach 1:
Instead of periodically opening the process chamber to remove contaminants, the system implements continuous gas flow through the chamber that constantly removes particulate contamination. The multiple partial gas flows operate continuously throughout the additive manufacturing process, maintaining low contaminant levels without requiring chamber opening, thus preserving manufacturing precision while achieving effective contamination control.
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 solution significantly improves the efficiency of particulate contamination removal, reducing the negative influence of contaminants on component quality and preventing interference with the energy beam, thereby enhancing the additive manufacturing process.
Implementation Method 1
a flow device which has the process chamber for generating a through-flowing, in particular inert, gas flow
Data Source
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AI summary
Device (1) for the additive manufacturing of three-dimensional objects (2) by successive layer-by-layer selective exposure and the associated successive layer-by-layer selective solidification of building material layers made of a building material (3) that can be solidified by means of an energy beam in a process chamber (7) on the device side with a defined process chamber height (H), comprising a flow device (8) which is configured to generate a gas flow (11), in particular an inert gas flow, through the process chamber (7) between an inlet area (9) and an outlet area (10), wherein the gas flow (11) flows through the process chamber (7) over the entire process chamber height (H), wherein the gas flow (11) is divided into several partial gas flows (11a - 11c) flowing in parallel one above the other through the process chamber (7), which differ in at least one flow parameter relating to the flow properties of the respective partial gas flows (11a - 11c). differentiate,is divided.