Additive Manufacturing Oxygen Control for Waste Particle Ignition
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Solution Overview
Problem
In additive manufacturing, particularly for metal objects, achieving a high product quality while maintaining safe operating conditions is challenging due to the risk of waste particle ignition caused by high oxygen levels during the solidification process.
Innovation Solution
A method and apparatus that control the oxidation of waste particles by managing oxygen levels within a specific range (50 ppm to 1000 ppm) and decouple the oxidation process from the solidification process, using an extracting and filtering system to prevent ignition, allowing for the reuse of gases and safe storage of waste particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a relative large amount of inert gas is supplied to maintain low oxygen level, then product quality is improved, but operating safety deteriorates due to risk of waste particle ignition
Solution Approach 1:
The patent extracts the harmful waste particles from the process chamber through a filtration system. By removing waste particles separately, the system can maintain low oxygen levels (improving product quality) without the harmful combination of low oxygen + high waste particle concentration that causes ignition. The extraction separates the quality control function from the safety function.
Solution Approach 2:
The patent changes the oxygen level parameter from very low (which causes ignition) to controlled low (50-1000 ppm range). This parameter optimization allows the system to maintain product quality while preventing waste particle ignition by keeping oxygen above the ignition threshold but low enough for quality manufacturing.
2Object-affected harmful factors
If a relative small amount of inert gas is supplied, then operating safety is improved by allowing higher oxygen level, but product quality deteriorates due to oxidization during solidification
Solution Approach 1:
The filtration system extracts waste particles from the process chamber, allowing the system to tolerate higher oxygen levels (improving safety) without compromising product quality. The extraction removes the oxidization source (waste particles) so oxygen can be maintained at safer levels.
Solution Approach 2:
The patent optimizes the oxygen level parameter to a specific range (50-1000 ppm) that balances quality and safety. This parameter change allows sufficient oxygen to prevent ignition while maintaining low enough levels to prevent excessive oxidization during solidification.
3Manufacturing precision
If oxygen level is allowed to become high, then waste particle ignition risk increases, but material oxidization during solidification is reduced
Solution Approach 1:
The patent extracts waste particles through a filtration system, decoupling the oxygen level control from waste particle management. This allows the system to maintain oxygen levels that prevent material oxidization while separately removing waste particles to prevent ignition.
Solution Approach 2:
The patent changes the oxygen level parameter to an optimized range (50-1000 ppm) that prevents both material oxidization and waste particle ignition. This parameter optimization resolves the contradiction by finding the sweet spot where neither harmful effect occurs.
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 approach ensures a high product quality by controlling the oxidation of waste particles below the ignition temperature, maintaining a safe operating environment, and reducing the risk of explosive conditions, while also allowing for efficient gas recycling and waste management.
Implementation Method 1
controlled oxidisation, of waste particles originate from said solidifying of said material, by controlling an oxygen level
Data Source
AI summary
A method for producing an object by additive manufacturing including receiving in a process chamber a bath of material wherein a surface level of the bath of material defines an object working area, solidifying by a solidifying device a selective layer-part of the material on the surface level, and controlled oxidisation, of waste particles originating from the solidifying of the material, by controlling an oxygen level, such that oxidised waste particles are obtained and ignition of the waste particles is avoided. An apparatus for producing an objet by additive manufacturing.