Binder Jetting Apparatus Actuatable Build Plate
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Solution Overview
Problem
Current additive manufacturing (AM) processes, such as binder jetting, face challenges in increasing operational speed and reducing part cost while improving the quality of the printed components.
Innovation Solution
A binder jet printing apparatus and method that includes a job box with an actuatable build plate, a supply box with an actuatable bottom platform, a print system with a binder source, a recoat system, and a cure system, allowing for independent movement and coordinated operation to efficiently apply and cure binder layers on powder, ensuring consistent layer thickness and powder distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional binder jetting processes are used, then part quality can be maintained, but operational speed is slow and throughput is limited
Solution Approach 1:
The apparatus divides the binder jetting process into distinct functional zones: a job box for binder application and curing, and a supply box for powder storage and recoating. This segmentation allows each zone to be optimized independently for its specific function, enabling faster operational cycles while maintaining part quality through specialized control of binder application and powder layer formation.
Solution Approach 2:
The build plate and bottom platform are made actuatable, allowing dynamic adjustment of their positions relative to each other. This dynamic capability enables precise control of powder layer thickness and build plate positioning, facilitating faster layer deposition while maintaining consistent layer quality and dimensional accuracy throughout the build process.
2Productivity
If faster build speeds are implemented, then throughput increases, but layer consistency and powder distribution may deteriorate
Solution Approach 1:
The supply box is equipped with a bottom platform that can be actuatable to pre-position and pre-distribute powder layers before they are transferred to the build plate. This preliminary action ensures that powder is properly prepared and distributed in advance, maintaining layer consistency even when the overall build speed is increased to improve throughput.
3Manufacturing precision
If traditional powder transfer methods are used, then equipment complexity is low, but powder distribution uniformity and layer thickness control are insufficient
Solution Approach 1:
The actuatable build plate and bottom platform work together to create equipotential conditions for powder transfer, ensuring uniform powder distribution across the layer. By coordinating the movement and positioning of these components, the system achieves consistent layer thickness and powder density without requiring overly complex additional mechanisms, balancing precision with reasonable equipment complexity.
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 throughput by reducing build time and improves part quality through precise control of binder application and powder layer formation, leading to faster production with potentially lower costs per part.
Implementation Method 1
a cure system configured to direct electromagnetic radiation onto the job box
Data Source
AI summary
A binder jet printing apparatus (10), along with methods of its use, is provided. The binder jet printing apparatus (10) may include: a job box (18) having a actuatable build plate (46) therein; a supply box (54) having a bottom platform (56) that is actuatable within the supply box (54); a print system including at least one print head (32) connected to a binder source (38) and configured to apply a pattern of binder onto an exposed powder layer (42) over the build plate (46) of the job box (18); a recoat system (16) including a recoater configured to move from the supply box (54) to the job box (18) to transfer powder from the supply box (54) to the job box (18) so as to form a new powder layer (48) over the build plate (46) of the job box (18); and a cure system (14) configured to direct electromagnetic radiation onto the job box (18).