Automated Additive Manufacturing De-Powdering With Vibratory Conveyance
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Solution Overview
Problem
The de-powdering process of additively manufactured three-dimensional objects, particularly those produced by binder jetting, is inefficient and prone to damage due to the lack of handling strength during chemical binder removal.
Innovation Solution
An automated de-powdering system that includes a separation station, a conveyor with agitation mechanisms, and a hopper to separate unbound powder from the object, utilizing vibration and fluidization to facilitate efficient and continuous de-powdering during the printing process.
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 objects are prone to damage
Solution Approach 1:
The de-powdering system is divided into distinct functional modules: a separation station for removing objects from the build plate, a conveyor system for transporting builds, and agitation mechanisms for powder removal. This segmentation allows each component to be optimized independently while working together to achieve automated high-speed de-powdering.
Solution Approach 2:
A sieve conveyor acts as an intermediary between the separation station and the agitation mechanisms. The conveyor receives builds from the separation station and transports them through the agitation zone, mediating the transfer of objects while enabling continuous processing and protecting objects from direct mechanical handling.
2Productivity
If automated de-powdering is implemented, then de-powdering efficiency improves, but the system complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated units: the separation station integrates build plate release and object extraction, the conveyor system combines transport and agitation functions, and the vibration mechanisms are integrated directly into the conveyor structure. This merging reduces the number of separate components while maintaining automated functionality.
Solution Approach 2:
The agitation mechanisms use self-contained vibration sources that generate their own oscillating motion without requiring external actuators for each processing point. The sieve conveyor uses its own motor to create both transport motion and the necessary agitation through its vibrating surface, making the system self-sufficient and reducing overall complexity.
3Strength
If chemical binder is used to join powder particles, then the green part can be formed, but the de-powdering process becomes difficult and time-consuming
Solution Approach 1:
The sieve conveyor incorporates vibration mechanisms that oscillate the conveyor surface at frequencies and amplitudes designed to loosen and separate unbound powder particles from the green part. This mechanical vibration accelerates the de-powdering process by physically disrupting the weak bonds between binder and loose powder, significantly reducing removal time while preserving the strength of bonded regions.
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 reduces de-powdering time and accommodates complex build orientations, minimizing damage to the objects by ensuring continuous separation of unbound powder while the printing process continues.
Implementation Method 1
one or more agitation mechanisms function to separate unbound powder build material from the one or more objects while the separated portion of the additive manufacturing build is being conveyed by the conveyor
Implementation Method 2
utilizing vibration and fluidization to facilitate efficient and continuous de-powdering during the printing process
Data Source
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AI summary
An automated de-powdering system comprises a separation station having a support structure configured to support a build box containing an additive manufacturing build. An actuator is configured to move at least a portion of the additive manufacturing build out of the build box and into a sleeve. A separation mechanism is configured to separate the portion of the additive manufacturing within the sleeve from a remainder of the additive manufacturing build. A de-powdering station includes a conveyor configured to convey the separated portion of the build away from the remaining portion of the build, and an agitation mechanism is configured to separate unbound powder build material from one or more objects of the portion while the portion is being conveyed by the conveyor.