Bi-directional Distributors for Additive Manufacturing Speed

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Solution Overview

Problem

Current additive manufacturing systems face inefficiencies in producing three-dimensional objects due to the time-consuming processes of layer-by-layer material deposition and agent delivery, which can be exacerbated by the need for frequent return movements of components and maintenance operations.

Innovation Solution

The system incorporates a bi-directional build material distributor and agent distributor, each with parking positions, allowing for simultaneous movement and maintenance while depositing layers, and an energy source that can apply energy uniformly or in a moving direction, reducing delays and increasing production speed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If additive manufacturing systems use traditional unidirectional material deposition and agent delivery, then the system can complete each layer, but the components must frequently return to starting positions and perform maintenance operations, which increases production time

Engineering Contradiction:

Improveproduction speedVSAvoidtime for component returns and maintenance

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent implements bi-directional movement capability for both the build material distributor and agent distributor, allowing them to travel in both forward and reverse directions along the build platform. This dynamic positioning system eliminates the need to always return to a single starting position, reducing idle travel time and enabling more efficient maintenance scheduling during layer transitions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system maintains continuous operation by enabling maintenance operations to be performed during layer transitions without stopping the overall manufacturing process. The bi-directional distributors can be repositioned and serviced while the build platform continues to receive new layers, ensuring that useful actions (material deposition and agent application) continue uninterrupted.

Inventive Principle:

Principle #20Continuity of useful action

2Ease of repair

If the build material distributor and agent distributor frequently return to parking positions, then components can be maintained, but the production cycle time increases due to these return movements

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidtime for return movements

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The bi-directional movement system allows distributors to access parking positions from either direction, providing flexibility in maintenance scheduling. Components can be maintained at optimal intervals without forcing the system to complete full return trips, as maintenance can be performed during layer transitions from either the forward or reverse direction.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system positions distributors at optimized locations before maintenance is needed, allowing maintenance operations to be performed proactively during layer transitions rather than reactively after components fail. This preliminary positioning reduces the need for emergency return trips and optimizes maintenance timing.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If the energy source applies energy uniformly to the entire layer, then solidification is consistent, but the process time increases compared to selective energy application

Engineering Contradiction:

Improvesolidification consistencyVSAvoidenergy application time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The energy source is configured to apply energy selectively to specific regions of the build platform rather than uniformly across the entire layer. This localized energy application maintains solidification consistency in the targeted areas while reducing the total energy application time, as only the necessary portions of each layer receive energy treatment.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system varies energy application parameters (such as energy distribution pattern, intensity, and duration) based on the specific requirements of different build regions. This parameter optimization allows consistent solidification in critical areas while minimizing energy application time overall, adapting the energy delivery to match the local solidification needs.

Inventive Principle:

Principle #35Parameter changes

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 configuration enhances the efficiency of additive manufacturing by allowing continuous layer deposition and agent delivery without the need for frequent component returns, reducing production time and enabling maintenance during operation, thus speeding up the generation of three-dimensional objects.

Implementation Method 1

selective solidification of successive layers of build material

Methodology Applied

Scientific EffectSelective solidification: Phase Change

Data Source

PatentUS11110652B2Generating a three-dimensional object

Publication Date: 2021.09.07 PERIDOT PRINT LLC

AI summary

According to one example, there is provided apparatus for generating a three-dimensional object. The apparatus comprises a build material distributor movable bi-directionally in a first axis to deposit successive layers of a build material on a support, and an agent distributor movable bi-directionally in a second axis different to the first axis to deliver an agent onto selected portions of successive layers of build material.