Build Chamber Vacuum Assembly for Automated Powder Removal
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Solution Overview
Problem
Manual removal of unused powder in additive manufacturing processes for aircraft parts is time-consuming and labor-intensive, increasing manufacturing costs.
Innovation Solution
An automated vacuum assembly system that includes duct lines with check valves and a powder receptacle, allowing for the automated removal of unused powder from the build chamber, reducing manual intervention and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual vacuuming is used to remove unused powder from the build chamber, then the build chamber can be reused for another build operation, but the process is time-consuming and labor-intensive
Solution Approach 1:
The system enables automated self-service powder removal through a vacuum assembly with a powder receptacle that automatically collects unused powder from the build chamber after each build operation, eliminating the need for manual intervention and significantly reducing the time required for build chamber preparation between operations
Solution Approach 2:
The manual mechanical vacuuming process is replaced with an automated vacuum assembly system that uses a vacuum apparatus connected to the build chamber through duct lines, transforming the labor-intensive manual operation into an automated mechanical system that operates without human intervention
2Ease of manufacture
If manual vacuuming is used to remove unused powder, then powder can be removed from the build chamber, but labor costs increase
Solution Approach 1:
The vacuum assembly with powder receptacle provides automated self-service functionality, allowing the system to remove its own waste powder without requiring external manual labor, thereby reducing labor costs while maintaining the powder removal capability
3Loss of time
If automated vacuum assembly is implemented, then powder removal time is reduced, but device complexity increases
Solution Approach 1:
The vacuum assembly is segmented into distinct functional components including the vacuum apparatus, duct lines with check valves, and a removable powder receptacle. This modular segmentation allows the system to achieve automation while keeping each component relatively simple and maintainable, balancing the trade-off between reduced time and increased 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 automated system significantly reduces the time and labor required for powder removal, lowering manufacturing costs and enhancing the efficiency of the additive manufacturing process.
Implementation Method 1
The vacuum assembly pulls the unused powder from the build chamber to the powder receptacle, via the one or more duct lines
Implementation Method 2
The check valve assembly comprises a check valve and an actuator to control a flow of the unused powder from the build chamber
Data Source
AI summary
There is provided an AM apparatus for an AM process. The AM apparatus has an AM assembly with a build chamber to support part(s) built with a powder, in a build operation. Unused powder accumulates in the build chamber during the build operation. The AM apparatus has a vacuum assembly with duct line(s) in flow communication with the build chamber, and a powder receptacle in flow communication with the duct line(s). The powder receptacle has coupling member(s) allowing the powder receptacle to be reversibly attached to the duct line(s). The vacuum assembly includes a vacuum apparatus coupled to, and in flow communication with, the powder receptacle, via vacuum duct line(s). The vacuum assembly pulls the unused powder from the build chamber to the powder receptacle, and provides an automated removal of the unused powder from the build chamber into the powder receptacle, to avoid manual removal of the unused powder.