Adjustable Laser Sintering Build Platform for Powder Reduction
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Solution Overview
Problem
Laser sintering systems lack the ability to variably adapt their installation volume to component size, resulting in unnecessary powder usage and increased costs due to inefficient space utilization.
Innovation Solution
The system incorporates additional side walls and a new construction platform with adjustable height, allowing for reduced installation space and targeted temperature control via sensors and heating/cooling elements, enabling adaptable powder usage and improved cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the build volume is reduced to match component size, then powder consumption is reduced and cost decreases, but temperature control becomes more difficult due to increased surface-to-volume ratio
Solution Approach 1:
The build chamber is divided into two separate chambers (upper and lower) that can be independently temperature-controlled. This segmentation allows each chamber to be optimized for its specific thermal requirements, with the lower chamber maintaining higher temperatures for powder bed stability and the upper chamber allowing faster cooling for component removal.
Solution Approach 2:
Different temperature zones are created within the build chamber by implementing separate heating and cooling control for upper and lower regions. This local quality approach enables the lower chamber to maintain the high temperatures needed for laser sintering while the upper chamber provides a cooler environment for rapid cooling, with each zone having tailored thermal properties.
2Loss of time
If cooling loops are added to the lower build chamber wall, then cooling speed increases and component removal time decreases, but device complexity increases
Solution Approach 1:
Cooling loops are integrated into the lower build chamber wall to enable rapid cooling of sintered components. These hydraulic cooling circuits circulate coolant through channels in the chamber wall, providing efficient heat removal and enabling faster component extraction without requiring separate cooling mechanisms.
Solution Approach 2:
The cooling function is merged with the build chamber structure itself by integrating cooling loops directly into the lower chamber wall. This combination eliminates the need for separate cooling apparatus and reduces overall system complexity while achieving rapid cooling objectives.
3Volume of stationary object
If the build platform is lowered to reduce build volume height, then installation space is reduced, but the rigid extension must be lowered by the same amount requiring base plate adaptation
Solution Approach 1:
The build platform is made height-adjustable through a positioning mechanism that allows vertical movement between multiple height levels. This dynamic adjustment capability enables optimization of build volume for different component sizes without requiring physical modification of the base plate or rigid extension, as the platform can be repositioned to accommodate various build height requirements.
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 solution reduces powder consumption, lowers component production costs, and enhances process reliability by allowing precise temperature control and faster cooling, reducing the risk of warping and optimizing powder reuse.
Implementation Method 1
laser sintering installation
Implementation Method 2
laser sintering systems
Implementation Method 3
The lower construction chamber can be equipped with thermocouples
Implementation Method 4
heating and cooling elements
Implementation Method 5
cooling loops
Implementation Method 6
The build platform should therefore be made of a material that, in addition to good temperature resistance, also possesses good thermal insulation properties
Data Source
Figure 1~2
Figure 2a~3
AI summary
The device for reducing lower installation space of a laser sintering plant, comprises introducing additional or new side walls in the lower installation space in an existing laser sintering plant and subjecting article adapted to the additional or new side walls, on the available installation platform of the plant. The available installation platform of the plant is replaced through a new installation platform that is adapted to the additional and/or new side walls. The new side wall consists of different or equally strong heating or cooling in different areas. The device for reducing lower installation space of a laser sintering plant, comprises introducing additional or new side walls in the lower installation space in an existing laser sintering plant and subjecting article adapted to the additional or new side walls, on the available installation platform of the plant. The available installation platform of the plant is replaced through a new installation platform that is adapted to the additional and/or new side walls. The new side wall consists of different or equally strong heating or cooling in different areas. The installation area is variably adjusted through a sliding- and detecting mechanism. The upper and lower installation areas are separated through a construction field plate (1a) that possesses good heat insulation characteristics.