Automated Additive Build Depowdering With Controlled Vibration
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Solution Overview
Problem
The challenge of efficiently removing unbound powder from additively manufactured green parts without causing damage during the de-powdering process, particularly in binder jet additive manufacturing, where the green parts lack sufficient handling strength.
Innovation Solution
An automated de-powdering system using an enclosure with a sleeve and vibration mechanisms to induce controlled vibrations, loosening unbound powder while protecting the green parts, combined with flow channels for evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If manual de-powdering methods are used, then powder removal can be achieved, but the green parts suffer from insufficient handling strength and may be damaged
Solution Approach 1:
The patent applies vibration mechanisms to the build plate or enclosure to induce controlled vibrations that loosen and facilitate removal of unbound powder from green parts. The vibration frequency and amplitude are controlled to be sufficient for powder removal but insufficient to damage the green parts, resolving the contradiction between effective powder removal and protection of fragile green parts
Solution Approach 2:
The patent replaces manual mechanical de-powdering operations with an automated vibration-based system. This substitution eliminates the need for direct mechanical contact and manual handling that could damage green parts, while still achieving effective powder removal through controlled vibrations
2Productivity
If automated de-powdering systems are implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The vibration mechanisms are integrated into the existing build plate or enclosure structure, allowing the same component to serve multiple functions: supporting the powder bed during manufacturing and providing vibration for de-powdering. This multi-functionality achieves automated de-powdering without adding separate complex systems
Solution Approach 2:
The patent combines the de-powdering function with the existing build plate or enclosure structure by integrating vibration mechanisms directly into these components. This merging approach achieves automation while minimizing additional device complexity by utilizing existing structural elements
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
Effectively separates unbound powder from the green parts without damaging them, enhancing the handling strength and facilitating efficient post-processing.
Implementation Method 1
a vibration mechanism actuatable to induce vibrations to the additive manufacturing build to loosen unbound powder material from the one or more objects
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A de-powdering system for additively manufactured objects includes an enclosure defining a cavity configured to support an additive manufacturing build. The enclosure includes a wall defining a lower boundary of the cavity, and the wall includes one or more flow channels. A sleeve is disposable in the cavity to at least partially surround the additive manufacturing build. At least one vibration mechanism is coupled to the sleeve and is actuatable to induce vibrations to the additive manufacturing build to loosen at least a portion of a powder build material from one or more objects suspended within the powder build material. The powder build material is removed from the cavity via the one or more flow channels.