Automated Additive Build De-Powdering With Vibration and Fluidization
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Solution Overview
Problem
The challenge in additive manufacturing, particularly in binder jetting, is the inefficient and potentially damaging manual de-powdering process of green parts, which lacks automation and is susceptible to damage due to insufficient handling strength during the removal of unbound powder.
Innovation Solution
An automated de-powdering system that includes a separation station with a sleeve and a separation mechanism, such as a cutting knife, to separate the powder from the object within a build box, combined with agitation mechanisms like vibration and fluidization to minimize disturbance, allowing for controlled and efficient removal of unbound powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual de-powdering is used, then the process is simple, but the de-powdering time is long and the green parts are susceptible to damage
Solution Approach 1:
The system uses automated mechanisms including a build plate mover to transfer builds, a separation mechanism to divide builds, and agitation mechanisms to remove powder automatically, eliminating manual labor and significantly reducing de-powdering time while preventing damage through controlled automated handling
Solution Approach 2:
The patent replaces manual mechanical de-powdering with an automated system that uses controlled agitation mechanisms (vibration, fluidization) to separate powder from green parts, substituting human-operated mechanical processes with automated mechanical and physical fields-based processes
2Productivity
If automated de-powdering system is used, then the de-powdering efficiency is improved, but the device complexity increases
Solution Approach 1:
The automated de-powdering system is designed to handle multiple build orientations and various types of green parts using the same separation mechanism and agitation mechanisms, making the complex system universally applicable to different additive manufacturing outputs while maintaining high efficiency
Solution Approach 2:
The system divides the de-powdering process into distinct stages: build transfer using build plate mover, separation using separation mechanism, and powder removal using agitation mechanisms, breaking down the complex automated process into manageable functional segments
3Quantity of substance
If aggressive powder removal methods are used, then the powder removal is thorough, but the green parts are damaged
Solution Approach 1:
The agitation mechanisms include vibration-based systems that gently oscillate the green parts to loosen and remove unbound powder through vibrational forces, achieving thorough powder removal while minimizing mechanical stress and damage to the relatively weak green parts
Solution Approach 2:
The system employs fluidization mechanisms that use gas or liquid flows to fluidize and remove loose powder from green parts through pneumatic or hydraulic action, providing thorough cleaning while using controlled fluid forces that are less damaging than direct mechanical contact
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 system significantly reduces de-powdering time and accommodates complex build orientations, minimizing damage to the green parts by automating the process and ensuring thorough powder removal.
Implementation Method 1
one or more agitation mechanisms to separate the unbound powder from the three-dimensional object while minimizing disturbance to the green additively manufactured objects
Implementation Method 2
one or more agitation mechanisms to separate the unbound powder from the three-dimensional object while minimizing disturbance to the green additively manufactured objects
Data Source
AI summary
An automated de-powdering system comprises a sleeve alignable with a build box where the build box includes one or more sidewalls and a build plate. The one or more sidewalls and the build plate define a build chamber configured to contain an additive manufacturing build where the additive manufacturing build includes one or more objects disposed within a powder build material. At least one actuator is actuatable to move the additive manufacturing build out of the build box and into the sleeve. At least one mechanism is actuatable to separate at least a portion of the powder build material from the one or more objects.