Additive Manufacturing Ram for Subsurface Powder Irradiation
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Solution Overview
Problem
Traditional additive manufacturing techniques face limitations in producing high-precision and complex parts with higher material quality due to restrictions and limitations in applicability, economy, and part formation.
Innovation Solution
An additive manufacturing system that includes a build volume with a powder and a beam generator to irradiate the powder within its outer boundary, using a ram to transmit the beam to an irradiation location, allowing for manufacturing within the powder and enabling complex geometries, higher powder packing density, and reduced exposure to ambient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional additive manufacturing techniques are used, then part formation is achieved, but manufacturing precision and material quality are limited
Solution Approach 1:
The patent transitions from surface-level irradiation to subsurface irradiation within the powder bed. The beam generator irradiates the powder at locations disposed within the outer boundary of the powder, enabling manufacturing in the third dimension (depth) rather than only at the surface. This dimensional change allows access to previously unreachable regions for high-precision feature creation.
Solution Approach 2:
The ram serves as an intermediary mechanism that positions and presses the powder while allowing beam transmission through its tip. This intermediary structure enables the beam to reach the powder subsurface through the ram tip opening, facilitating precise irradiation at controlled depths without direct contact between the beam source and the powder.
2Shape
If traditional additive manufacturing techniques are used, then part formation is achieved, but complexity of parts is limited
Solution Approach 1:
By enabling irradiation within the powder bed at various depths rather than only at the surface, the system can create complex three-dimensional geometries that were previously inaccessible. The ability to position the beam at subsurface locations allows for internal structures, overhangs, and complex shapes to be formed directly during manufacturing.
Solution Approach 2:
The manufacturing process segments the powder bed into multiple irradiation zones at different depths and locations. The beam generator can selectively irradiate specific regions within the powder outer boundary, allowing complex geometries to be built up layer by layer through controlled segmentation of the irradiation process.
3Reliability
If traditional additive manufacturing techniques are used, then part formation is achieved, but material quality is limited
Solution Approach 1:
The patent maintains the powder bed in a controlled environment throughout the manufacturing process. By irradiating the powder at subsurface locations within the outer boundary and eliminating the need for superficial powder layers, the system reduces exposure to ambient conditions. The enclosed powder bed acts as a protective inert environment that prevents contamination and maintains material integrity.
Solution Approach 2:
The ram tip opening serves as a controlled intermediary pathway that allows beam transmission while maintaining the protective enclosure around the powder. This intermediary structure enables irradiation at depth while preserving the controlled atmosphere, thereby protecting the material from harmful ambient conditions during the manufacturing process.
4Productivity
If irradiation occurs at surface level, then manufacturing process is simple, but build time increases
Solution Approach 1:
The system enables continuous irradiation of the powder bed at subsurface locations without requiring repeated surface preparation or layer-by-layer surface irradiation. The beam generator can continuously process material at depth within the powder outer boundary, maintaining continuous productive action and reducing idle time associated with surface-level processing requirements.
Solution Approach 2:
By moving the irradiation process from the surface to subsurface locations within the powder, the system eliminates the need for repeated surface leveling and preparation cycles. This dimensional shift to depth-based irradiation allows for more efficient continuous manufacturing, reducing overall build time despite the added complexity of the irradiation system.
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 the creation of previously unobtainable geometric structures, reduces build time, and enhances material quality by allowing irradiation within the powder, eliminating the need for superficial powder layers and minimizing ambient condition exposure.
Implementation Method 1
Known techniques include, for example, photopolymerization manufacturing, selective laser sintering/melting
Implementation Method 2
beam generator configured to generate a beam to irradiate the powder
Implementation Method 3
a ram defining a passthrough configured to transmit the beam to an irradiation location disposed within the outer boundary of the powder
Data Source
AI summary
Additive manufacturing systems and methods. An additive manufacturing system includes a build volume; a powder disposed in the build volume, the powder occupying at least a portion of the build volume and having an outer boundary; a beam generator configured to generate a beam to irradiate the powder; and a ram defining a passthrough configured to transmit the beam to an irradiation location disposed within the outer boundary of the powder.