Automated Additive Manufacturing Material Handling

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Solution Overview

Problem

Conventional additive manufacturing systems face inefficiencies and contamination issues due to manual handling of building materials like powder and binder, which are time-consuming and prone to errors, especially with reactive or solvent-based materials, leading to decreased quality and efficacy.

Innovation Solution

An automated additive manufacturing system incorporating a powder material handling system, a liquid material handling system, and a depowder system that ensures gastight connections and automated transfer of materials, reducing exposure to oxygen and debris, and improving precision and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling of building materials is used, then ease of operation is improved, but productivity deteriorates due to time-consuming operations

Engineering Contradiction:

Improveease of operationVSAvoidproductivity

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system employs automated material handling where the machine itself performs loading and removal operations without human intervention. The automated material handling system includes robotic end effectors that grasp, lift, and position building materials, as well as automatically remove excess materials and work products, enabling the system to serve itself

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with automated mechanical systems including robotic manipulators, automated conveyors, and controlled material handling mechanisms that perform loading, positioning, and removal operations, substituting human labor with automated mechanical systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual handling of building materials is used, then device complexity is reduced, but manufacturing precision deteriorates due to material handling errors

Engineering Contradiction:

Improvedevice complexityVSAvoidmanufacturing precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The automated system performs material handling operations autonomously with precise control, where the machine itself manages the complex tasks of material loading, positioning, and removal without human intervention, ensuring consistent precision

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates sensors and control systems that monitor material handling operations in real-time, providing feedback to adjust positioning and placement accuracy, ensuring precise material deposition and work product removal

Inventive Principle:

Principle #23Feedback

3Ease of operation

If manual handling of building materials is used, then ease of operation is improved, but reliability deteriorates due to exposure to open environment causing contamination

Engineering Contradiction:

Improveease of operationVSAvoidreliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system employs sealed enclosures and protective barriers that contain the building materials and work products, preventing exposure to the open environment and contamination from oxygen or debris while maintaining automated operation

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The automated system operates within controlled environments that may include inert atmospheres or sealed chambers, protecting reactive or solvent-based building materials from degradation while enabling automated handling operations

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Productivity

If automated material handling system is used, then productivity is improved, but device complexity increases

Engineering Contradiction:

ImproveproductivityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The automated material handling system is designed with multi-functional components that can perform multiple operations such as grasping, lifting, positioning, and removing materials, reducing the number of separate devices needed while maintaining high productivity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system combines material handling functions with the additive manufacturing process itself, integrating loading, deposition, and removal operations into a unified automated system that operates continuously

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240157646A1Liquid and powder material handling systems within additive manufacturing and methods for their use

Publication Date: 2024.05.16 GENERAL ELECTRIC CO

AI summary

The present disclosure is directed to additive manufacturing systems, components therein, and methods for their use. The additive manufacturing system comprises a powder material handling system comprising a virgin powder inlet. The virgin powder inlet is coupled to a virgin powder drum and configured to receive a virgin powder from the virgin powder drum. The additive manufacturing system further comprises a liquid material handling system comprising a binder inlet. The binder inlet is coupled to a binder drum and configured to receive a binder from the binder drum. The additive manufacturing system also comprises an additive manufacturing machine coupled to the powder material handling system and the liquid material handling system. The additive manufacturing machine receives the virgin powder and the binder from the powder material handling and liquid material handling systems and is configured to manufacture a work product using the virgin powder and the binder.