Blocker Plate Additive Manufacturing Chamber
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
As additive manufacturing processes produce larger parts, the accumulation of excess powdered material becomes significant, increasing the size and weight borne by the manufacturing machine's components, leading to higher costs and complexity in controlling the fabrication process.
Innovation Solution
The implementation of a blocker plate with a sidewall barrier in the additive manufacturing machine, which blocks excess material from falling onto the work surface and directs it to a removal system, reducing the load on the machine's actuator and allowing precise incremental movement for accurate layer deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If larger parts are fabricated in additive manufacturing, then part size and manufacturing capability are improved, but excess powdered material accumulation increases machine weight and complexity
Solution Approach 1:
The work chamber is segmented into a fabrication zone and an excess material containment zone using a containment structure. This allows excess material to be isolated in a separate region, preventing it from adding weight to the moving work surface while still allowing large parts to be fabricated.
Solution Approach 2:
Excess material is extracted and removed from the fabrication zone using a removal device. This prevents accumulation of excess material on the work surface, maintaining reduced weight on moving components while enabling continued fabrication of large parts.
2Volume of moving object
If larger parts are fabricated in additive manufacturing, then part fabrication capability is improved, but control complexity and costs increase
Solution Approach 1:
By segmenting the chamber into distinct zones with a containment structure, the system simplifies control of excess material. The containment structure passively directs excess material to a removal device, reducing the complexity of active control systems needed to manage material distribution in large chambers.
3Ease of manufacture
If excess material is allowed to accumulate on work surface, then material deposition is simplified, but interference with part geometry and precision occurs
Solution Approach 1:
The containment structure extracts and isolates excess material from the fabrication zone, directing it to a removal device. This maintains the simplicity of material deposition while preventing excess material from interfering with part geometry, thereby preserving manufacturing precision.
Solution Approach 2:
The containment structure acts as an intermediary between the material deposition process and the part fabrication zone. It allows material to be deposited freely while mediating to prevent excess material from reaching and interfering with the part geometry.
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 effectively manages excess material, reducing the load on the machine's components, maintaining precise control and feasibility in fabricating larger parts by preventing excess material from interfering with the part geometry and allowing for efficient removal, thus enhancing the economic viability and capability of the process.
Implementation Method 1
directing energy on portions of the deposited material according to a defined part geometry
Implementation Method 2
a blocker plate disposed between the material applicator and the work surface for blocking a portion of material deposited by the material applicator
Data Source
AI summary
A disclosed additive manufacturing machine (10) includes a work surface (16) for supporting fabrication of part (18) and a housing (50) defining a chamber (48) over the work surface (16). A material applicator (24) supported on the housing (50) deposits material (26) onto the work surface (16) and a blocker plate (40) disposed between the material applicator (24) and the work surface (16) for blocking a portion of material (26) deposited by the material applicator (24). An energy directing device (20) is supported on the housing (50) and directing energy (22) within the chamber (48) to form the part (18).