Angular Build Platform Motion for Large-Scale Powder Bed Printing
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Solution Overview
Problem
Conventional additive manufacturing systems face limitations in producing large objects with precision and efficiency due to the size constraints of the powder bed, which can lead to reduced scan quality and increased material waste, especially when trying to build objects larger than the machine's capabilities.
Innovation Solution
The implementation of a rotating build platform and mobile build unit assembly with a positioning mechanism allowing two- or three-dimensional movement and rotation, along with a selective recoating mechanism, enables the formation of large objects by depositing powder and bonding it between outer and inner build envelopes, reducing the need to lower the build platform and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the powder bed size is increased to manufacture larger objects, then the manufacturing capability is improved, but the scan quality deteriorates due to the large angle of incidence
Solution Approach 1:
The build platform is rotated during the additive manufacturing process to dynamically change the orientation of the build surface relative to the energy beam. This rotation allows the system to maintain a favorable angle of incidence for scanning while building larger objects, thereby preserving scan quality without limiting the maximum object size that can be manufactured.
2Volume of moving object
If the powder bed size is increased to manufacture larger objects, then the manufacturing capability is improved, but the system weight increases beyond the capabilities of steppers used to lower the build platform
Solution Approach 1:
Instead of using a large, heavy powder bed to accommodate bigger objects, the system uses a smaller powder bed that rotates dynamically. This approach allows the build volume to be effectively increased through rotation while keeping the actual powder bed size and weight within the capabilities of existing stepper motors to lower the build platform.
3Volume of moving object
If conventional systems are used to manufacture large objects, then the object size capability is improved, but the material waste increases
Solution Approach 1:
The rotating build platform enables more efficient powder utilization by maintaining optimal scanning angles throughout the build process. This dynamic approach allows for better powder distribution and reduced spillover or waste, enabling large object manufacturing with improved material efficiency compared to static conventional systems.
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 allows for the precise and efficient production of large-scale objects, such as annular components, with improved precision and reduced material waste, enabling the creation of complex components that would be challenging for conventional systems to handle.
Implementation Method 1
an irradiation emission directing device that directs an energy beam, for example, an electron beam or a laser beam, to sinter or melt a powder material
Implementation Method 2
melting entails fully melting particles of a powder to form a solid homogeneous mass
Implementation Method 3
Apparatus and method for angular and rotational additive manufacturing... rotating build platform... mobile build unit assembly with a positioning mechanism allowing two- or three-dimensional movement and rotation
Data Source
AI summary
An additive manufacturing apparatus is provided and may include at least one build unit; a build platform; and at least one collector positioned on the apparatus such that the at least one collector contacts an outer surface of a build wall as the build wall is formed during a build. Methods are also provided for manufacturing at least one object.