Additive Manufacturing Recoating and Beam Calibration Under Collision Risk
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing technologies face challenges in accurately solidifying selective parts of layers, particularly in metal objects, and in achieving uniform and efficient deposition of material layers with minimal damage to recoating devices.
Innovation Solution
The apparatus incorporates a registering device for on-site calibration using an imaging device to control the position of electromagnetic radiation, and a recoating device with elongated levelling members that deflect upon encountering excessive force to prevent damage and ensure uniform layer deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If off-site calibration using test patterns is used, then calibration can be performed, but it is time-consuming and expensive
Solution Approach 1:
The system performs calibration automatically using the registering device to capture the actual position of electromagnetic radiation on the material surface, eliminating the need for external off-site calibration services. The control unit processes the captured position information and generates correction values autonomously, making the system self-calibrating and significantly reducing both time and cost.
Solution Approach 2:
The registering device continuously monitors the actual position of electromagnetic radiation on the material surface and feeds this information back to the control unit. The control unit compares the actual position with the intended position and adjusts the deflection control accordingly, creating a closed-loop feedback system that maintains calibration accuracy without time-consuming external intervention.
2Strength
If rigid levelling members are used, then structural strength is maintained, but damage occurs when encountering protruding parts
Solution Approach 1:
The levelling members are designed with flexible connections that allow them to dynamically adapt their position when encountering protruding parts of the object. Instead of being rigid and prone to damage, the levelling members can deflect or move aside, transforming from a static rigid structure to a dynamic adaptable component that preserves both strength and reliability.
Solution Approach 2:
The flexible connection design anticipates potential collisions with protruding parts by built-in compliance. This beforehand cushioning allows the levelling member to absorb impact forces through elastic deformation or controlled movement, preventing damage to both the levelling member and the object, thereby ensuring continuous reliable operation.
3Reliability
If the levelling element moves upon encountering force, then damage is prevented, but uniformity of layer deposition may be affected
Solution Approach 1:
The recoating device is divided into multiple independent levelling members, each capable of moving independently upon encountering force. This segmentation ensures that when one levelling member deflects to avoid damage, others can continue to maintain uniform layer deposition, distributing the impact across multiple segments rather than compromising the entire system's 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 enhances the accuracy and efficiency of layer solidification and deposition, reducing the need for off-site calibration and minimizing damage to recoating devices, thereby improving the overall precision and durability of the manufacturing process.
Implementation Method 1
a solidifying device for solidifying a selective layer-part of the material on the surface level by means of electromagnetic radiation
Implementation Method 2
The registering device comprises at least one imaging device, in particular an optical imaging device
Implementation Method 3
at least an end of the levelling element facing the surface of the bath is arranged to be displaceable in at least a direction substantially transversal to the plane defined by the surface (L) of the bath upon encountering a force exceeding a threshold
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an apparatus and method for producing an object by means of additive manufacturing. The apparatus comprises a process chamber for receiving a bath of material which can be solidified. The apparatus further comprises a structure for positioning the object in relation to the surface level of the bath of material. The apparatus also comprises a solidifying device for solidifying a layer of the material on the surface. Further, the apparatus comprises an extraction device fluidly connected to the process chamber and arranged for extracting material out of the process chamber. Moreover, the apparatus comprises blowing means for inducing a gaseous flow in the process chamber affecting the material to be extracted. The blowing means comprise a plurality of blow nozzles fluidly connected to the process chamber and directed in a plurality of different directions.