Brush Cleaning Device for Additive Manufacturing Layering
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Solution Overview
Problem
In powder-based additive manufacturing, volatile and sticky powder tends to accumulate and agglomerate on surfaces of the layering device, leading to errors in layer thickness and reduced part quality, as agglomerates fall into the powder deposition zone during the manufacturing process.
Innovation Solution
A cleaning device with a brushing mechanism is integrated into the layering device's path, which includes brushes that dislodge agglomerates from smoothing and deposition surfaces, and a suction system to evacuate them before they reach the powder deposition zone, ensuring effective cleaning and maintaining desired layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If powder-based additive manufacturing is performed using a layering device with smoothing means, then parts can be manufactured with controlled layer deposition, but powder accumulates and forms agglomerates on the smoothing surfaces which fall into the powder deposition zone and modify layer thickness
Solution Approach 1:
The cleaning device performs preliminary cleaning of the smoothing means before the powder deposition cycle begins. The brushing mechanism removes accumulated powder and agglomerates from the smoothing cylinder surface in advance, preventing them from falling into the deposition zone during subsequent operations.
Solution Approach 2:
The cleaning device is integrated into the layering device itself, enabling the system to clean its own components autonomously. The brushing mechanism is positioned to contact the smoothing cylinder during the layering device's movement, allowing self-cleaning without external intervention.
2Productivity
If the layering device operates continuously to maintain productivity, then manufacturing efficiency is improved, but powder agglomerates accumulate on smoothing surfaces and compromise part quality
Solution Approach 1:
The cleaning operation is integrated into the continuous movement cycle of the layering device. The brushing mechanism operates continuously during the device's traversal, maintaining clean smoothing surfaces throughout the manufacturing process without interrupting productivity.
Solution Approach 2:
Cleaning occurs continuously in advance of potential agglomerate formation affecting the deposition zone. The brushing mechanism maintains the smoothing surface in a clean state proactively, preventing quality issues before they occur during continuous operation.
3Manufacturing precision
If cleaning operations are performed to remove powder agglomerates, then layer thickness precision is improved, but the device complexity increases due to additional cleaning components
Solution Approach 1:
The cleaning function is merged with the existing layering device structure. The brushing mechanism is integrated into the movement system, utilizing the same actuation and support structures already present in the layering device, thereby minimizing additional complexity.
Solution Approach 2:
The layering device's movement mechanism serves dual purposes: both depositing powder layers and enabling the cleaning brush to contact the smoothing cylinder. The same mechanical infrastructure supports both manufacturing and cleaning operations, reducing overall system 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
The solution significantly reduces the formation and presence of powder agglomerates in the powder deposition zone, enhancing the quality of manufactured parts by maintaining consistent layer thickness, especially when the required layer thickness is in the order of ten micrometers.
Implementation Method 1
a brushing device for brushing at least one surface of the powder smoothing means
Implementation Method 2
the brushing device makes it possible to brush the surfaces of the means for smoothing the powder and to dislodge the agglomerates therefrom
Implementation Method 3
the cleaning device comprises a powder suction device for evacuating the powder sucked up by this suction device towards a zone of the installation, called the dust removal zone
Data Source
AI summary
The invention relates to a powder-based additive manufacturing unit (10) comprising a device (14) for layering the powder, which can be moved along a path connecting a start zone (A) and an end zone (B). The layering device (14) comprises powder-smoothing means (35) for depositing the powder in a powder deposition zone (P) located between the start zone (A) and the end zone (B). The unit (10) also comprises a cleaning device (60) located on the path of the layering device (14), said cleaning device (60) comprising a brush device (62) for brushing at least one surface of the powder-smoothing means (35).