Broad Frequency Filter for Powder Sieving
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Solution Overview
Problem
Additive manufacturing machines face challenges in efficiently recycling and sieving powders due to the size and configuration of printed objects, leading to difficulties in powder removal and collection.
Innovation Solution
A sieving system incorporating a broad frequency filter with a support structure and a powder mass control assembly, which includes a movable filter housing with a first rigid filter and a second flexible filter, allowing powders smaller than a predetermined threshold to pass through while restricting larger particles, and a method for reclaiming unused powder by filtering and controlling the powder mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single rigid filter is used for powder sieving, then the filter structure is simple and easy to manufacture, but it cannot effectively separate particles across a broad size range and causes excessive powder retention
Solution Approach 1:
The filter system is divided into multiple filter elements (first filter, second filter, third filter) with different pore sizes arranged in series. Each filter targets a specific particle size range, enabling efficient separation across a broad spectrum while maintaining individual filter simplicity for easy manufacturing
Solution Approach 2:
The filter elements have progressively changing pore size parameters from the first to the third filter. This parameter gradient allows each subsequent filter to catch particles that passed through previous filters, improving overall separation efficiency without requiring any single filter to be overly complex
2Device complexity
If the filter housing is stationary, then the system structure is simple, but powder accumulation on the filter surface reduces separation efficiency over time
Solution Approach 1:
The filter housing is made movable relative to the support structure, transforming the static filter system into a dynamic one. This movement prevents powder accumulation by continuously refreshing the filter surface, maintaining consistent separation efficiency without requiring complex additional mechanisms
Solution Approach 2:
The filter housing performs periodic movement cycles relative to the support structure. This periodic action clears accumulated powder from the filter surface at regular intervals, ensuring reliable and consistent separation performance throughout operation without needing continuous complex control systems
3Ease of operation
If no powder mass control is implemented, then the system operation is simple, but uncontrolled powder mass leads to inefficient recycling and loss of valuable material
Solution Approach 1:
A powder mass control system with sensors and feedback control is implemented to monitor and regulate the mass of powder being recycled. The system automatically adjusts operation parameters based on real-time powder mass measurements, preventing material loss while maintaining ease of operation through automated control
Solution Approach 2:
The powder mass control assembly autonomously manages powder flow and mass without requiring manual intervention. The system self-regulates to optimize recycling efficiency and minimize material loss, combining automated intelligence with simple operation for the user
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 effectively recovers and recirculates powders by separating particles based on size, ensuring efficient powder recycling and maintaining a desired mass distribution, enhancing the powder reclamation process in additive manufacturing.
Implementation Method 1
a first filter fixed relative to the filter housing, the first filter being substantially rigid; and a second filter coupled within the filter housing adjacent to the first filter, the second filter defining a maximum deflection from the first filter greater than 1/4 inch (6.35 mm) and less than 1 inch (25.4 mm)
Data Source
AI summary
A sieving system for a powder is provided. The sieving system includes a support structure; a filter housing movable relative to the support structure, the filter housing defining an inlet and an outlet, the filter housing comprising a broad frequency filter disposed between the inlet and the outlet, the broad frequency filter configured to restrict a first portion of the powder larger than a predetermined threshold from reaching the outlet; and a powder mass control assembly configured to determine data indicative of a powder mass within a portion of the sieving system and control one or more operations of the sieving system based on the determined data indicative of the powder mass.