Adjustable Slit Powder Dispenser for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing techniques require large quantities of powder, leading to inefficient use and storage due to fixed powder dispensing mechanisms that cannot adjust to varying working spaces, resulting in excess powder usage and inefficiencies.
Innovation Solution
A powder dispenser with a movable base plate and adjustable slit, combined with levelling elements and energy emitters, forms containment walls to define a confined working space, allowing precise powder deposition and reduction of unnecessary powder usage by adjusting the powder outlet length based on the component's dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed-size horizontal slit is used for powder dispensing, then the dispenser structure is simple, but the powder distribution is inefficient and excessive powder is used
Solution Approach 1:
The patent applies the dynamics principle by making the slit length adjustable rather than fixed. The slit length can be dynamically changed to match the dimensions of the component being manufactured, allowing precise control over the powder distribution area and reducing waste.
Solution Approach 2:
The patent changes the parameter of slit length from a fixed value to an adjustable variable. By modifying this geometric parameter according to the component size, the system optimizes powder usage while maintaining structural simplicity.
2Ease of manufacture
If the powder outlet length is fixed, then the dispenser is easier to manufacture, but it cannot adapt to different component sizes and uses unnecessary powder
Solution Approach 1:
The dispenser incorporates an adjustable mechanism that allows the slit length to be dynamically modified. This dynamic feature enables the same dispenser structure to adapt to different component sizes without requiring multiple specialized devices.
Solution Approach 2:
By making the slit length adjustable, a single dispenser design can serve multiple functions for manufacturing components of various sizes, enhancing versatility while maintaining ease of manufacture through a standardized base design.
3Area of stationary object
If a large platform is used to accommodate all powder, then the entire volume of powder can be deposited, but most of the powder remains unused around the component
Solution Approach 1:
The patent applies local quality by concentrating powder deposition only in the areas where it is needed - specifically within the bounding box of the component. The adjustable slit ensures powder is delivered precisely to the relevant zones rather than uniformly across the entire platform surface.
Solution Approach 2:
The invention extracts only the necessary portion of powder for the specific component being manufactured. By adjusting the slit length to match the component dimensions, the system takes out exactly the required amount of powder, leaving the rest unused.
4Device complexity
If the slit length cannot be adjusted, then the dispenser structure is simpler, but powder falls outside the working space when dispenser is in areas with smaller length
Solution Approach 1:
The adjustable slit length provides a dynamic adaptation mechanism that responds to the varying dimensions of different components. This ensures powder deposition accuracy is maintained across different working conditions without significantly complicating the dispenser structure.
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
The solution significantly reduces powder consumption by optimizing the working space and allowing for precise powder distribution, minimizing waste and storage needs while maintaining the quality of the additive manufacturing process.
Implementation Method 1
specific areas thereof are melted through the scanning of a focused energy beam, typically a laser beam or an electron beam
Implementation Method 2
specific areas thereof are melted through the scanning of a focused energy beam, typically a laser beam or an electron beam
Implementation Method 3
The dispenser also comprises at least one levelling element, which is arranged downstream of the slit in the advancing direction and projects downwards with respect to the dispenser
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A powder dispenser (14) has a vertical channel (55), which, at the top, is adapted to communicate with a tank for receiving the powder and inferiorly ends at an opening (26), which is elongated along a horizontal direction and comprises an outlet portion (51) for letting the powder fall; the dispenser further has a shutter device (50) for varying the length of the outlet portion (51) with respect to the total length of the opening (26) along its horizontal axis (36).