Additive Manufacturing Powder Levelling with Variable Speed Control
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Solution Overview
Problem
The challenge in additive manufacturing, particularly for metal objects, is to achieve low manufacturing costs while maintaining high object quality, with a focus on minimizing operational costs and total object lead time.
Innovation Solution
A method utilizing a control unit to vary the speed of a levelling unit's displacement based on its position and the distance from a support in a powdered material bath, combined with varying parameters such as layer thickness and replenishment intervals, to optimize the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the levelling unit operates at constant high speed throughout the entire bath surface, then productivity increases and manufacturing time decreases, but manufacturing precision deteriorates in critical areas
Solution Approach 1:
The patent applies local quality by varying the levelling speed according to the specific requirements of different regions. Critical areas (where objects are built) receive slower levelling speed for high precision, while non-critical areas (empty regions) receive faster levelling speed for high productivity. This is achieved through a control unit that adjusts the levelling unit's speed based on position information and object geometry data.
Solution Approach 2:
The patent implements dynamics by making the levelling speed variable rather than constant. The control unit dynamically adjusts the levelling unit's displacement speed during operation, transitioning between high speed in non-critical areas and low speed in critical areas. This dynamic speed adjustment allows the system to adapt to different positional requirements throughout the build process.
2Manufacturing precision
If the levelling unit operates at constant low speed throughout the entire bath surface, then manufacturing precision is maintained in critical areas, but productivity decreases and manufacturing time increases
Solution Approach 1:
The patent applies local quality by varying the levelling speed according to the specific requirements of different regions. Critical areas (where objects are built) receive slower levelling speed for high precision, while non-critical areas (empty regions) receive faster levelling speed for high productivity. This is achieved through a control unit that adjusts the levelling unit's speed based on position information and object geometry data.
Solution Approach 2:
The patent implements dynamics by making the levelling speed variable rather than constant. The control unit dynamically adjusts the levelling unit's displacement speed during operation, transitioning between high speed in non-critical areas and low speed in critical areas. This dynamic speed adjustment allows the system to adapt to different positional requirements throughout the build process.
3Device complexity
If uniform levelling speed is used across the entire bath, then device complexity remains low, but loss of time occurs due to inefficient processing of different area types
Solution Approach 1:
The patent applies feedback by implementing a control unit that receives position information from sensors or encoders on the levelling unit and object geometry data, then adjusts the levelling speed accordingly. The control unit continuously monitors the levelling unit's position and automatically modifies the displacement speed to match the requirements of the current area being levelled, creating a closed-loop control system that optimizes both time and precision.
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 reduces valuable machine time and maintains or enhances object quality by allowing faster processing of less critical areas and slower processing of critical areas, thereby achieving lower manufacturing costs without compromising quality.
Implementation Method 1
a solidifying device for solidifying a selective layer-part of the powdered material
Implementation Method 2
a computer controlled additive manufacturing apparatus may be used which sequentially sinters a plurality of layer-parts
Implementation Method 3
a levelling unit which is arranged to be displaced along the surface level of the bath of powdered material for levelling the surface level of the bath of powdered material
Data Source
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AI summary
The present disclosure relates to an apparatus and method for producing an object by means of additive manufacturing, the apparatus comprising a process chamber for a bath of powdered material which can be solidified, a support for positioning the object in relation to a surface level of the bath, a solidifying device for solidifying a selective layer-part of the material, and a recoating device comprising a supply unit for supplying material to the bath and a levelling unit for levelling the surface level. The apparatus further comprises a control unit for controlling the displacement of the levelling unit and configured such that a speed of displacement of the levelling unit is varied during the production of the object, in dependence of a position of the levelling unit along the surface during levelling, and/or a parameter related to a distance between the surface level and the support.