Additive Manufacturing Gas Flow Segmentation
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Solution Overview
Problem
In laser sintering/melting additive manufacturing systems, smoke and particulate matter accumulation within the chamber interferes with the laser beam and reduces the quality of the resulting object, as existing upper gas flow methods are inefficient in removing these contaminants, especially in the lower chamber region, leading to chaotic flow and recirculation.
Innovation Solution
The implementation of a combination of upper and lower gas flows, where the lower gas flow is directed towards the build platform with guided streams and adjustable flow characteristics, to enhance the removal of smoke and particulate matter from the chamber, reducing gas entrainment and recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If only an upper gas flow is used to remove smoke and particulate matter, then the gas flow system is simple, but the removal efficiency in the lower chamber region is poor and causes chaotic flow with recirculation
Solution Approach 1:
The gas flow system is segmented into multiple independent flow sources: an upper gas flow inlet and a lower gas flow inlet, each capable of being controlled separately. This segmentation allows targeted removal of contaminants in different chamber regions without creating chaotic recirculation patterns, as each flow source can be optimized for its specific zone.
Solution Approach 2:
The gas flow control transitions from a single-dimensional (upper only) approach to a multi-dimensional approach by adding vertical stratification with both upper and lower inlets. This dimensional change enables three-dimensional flow management that eliminates dead zones and recirculation while maintaining system simplicity through modular inlet designs.
2Object-affected harmful factors
If an upper gas flow is introduced to remove smoke and particulate matter, then some contaminants are removed from the upper chamber, but the lower chamber region accumulates smoke and particulate matter
Solution Approach 1:
Different regions of the chamber are treated with locally optimized gas flow characteristics. The lower gas inlet is positioned and configured to specifically address contaminant removal in the lower chamber region where the build platform is located, while the upper inlet handles the upper region. This local quality approach ensures comprehensive contaminant removal throughout the entire chamber volume, preventing deposition on the build platform and maintaining manufacturing 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 improves the quality of the manufacturing process by effectively removing smoke and particulate matter, leading to enhanced object quality and efficiency in additive manufacturing systems.
Implementation Method 1
supplying a lower gas flow into the chamber towards the build platform
Implementation Method 2
supplying an upper gas flow into the chamber horizontally above the build platform
Implementation Method 3
applying a focused energy beam to at least a portion of the bed of the powder material deposited on the build platform to form a solidified layer
Implementation Method 4
a focused energy source (e.g., an electron beam, a laser beam) to sinter or melt a powder material
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An additive manufacturing (AM) system (10) includes a housing (18) defining a chamber (20) and a build platform (22) disposed in a lower portion (82) of the chamber. The AM system includes an upper gas inlet (44) disposed in a side-wall (50) and in an upper portion (42) of the chamber and configured to supply an upper gas flow (46) parallel to the build platform. The AM system includes a lower gas inlet (84) in the lower portion of the chamber, wherein the lower gas inlet includes one or more pairs of dividing walls (90, 92, 142, 146, 150) extending from the side-wall toward the build platform and configured to guide the lower gas flow at one or more flow angles (120, 145, 149, 153) with respect to the build platform. The AM system includes at least one gas delivery mechanisms (74, 106) to regulate flow characteristics of the upper and lower gas flows, and includes a gas outlet (108) to discharge the upper and lower gas flows from the chamber.