3D Printer Build Module Sealing for Inert Atmosphere Printing
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Solution Overview
Problem
Existing 3D printing technologies face challenges in preventing exposure of starting materials and remnants to ambient atmospheric conditions, such as oxygen or humidity, which can affect the printing process and the quality of the 3D objects produced.
Innovation Solution
The method involves a controlled environment using a build module and a processing chamber with separate atmospheres, where the build module is reversibly sealed and can be engaged and disengaged from the processing chamber without human intervention, using a first and second controller to manage the printing process and maintain an inert atmosphere, allowing for efficient printing of 3D objects using granular materials like metals, ceramics, or carbon.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the build module is sealed and engaged with the processing chamber to maintain inert atmosphere, then material degradation is reduced, but device complexity increases
Solution Approach 1:
The system is divided into separate modules: a build module for 3D printing and a processing chamber for material storage and post-processing. Each module can be independently sealed and controlled, allowing the inert atmosphere to be maintained only where needed rather than throughout the entire system.
Solution Approach 2:
A load lock chamber serves as an intermediary between the build module and the processing chamber. This intermediate chamber allows for atmosphere transitions and module engagement/disengagement without compromising the inert atmosphere in the build module, simplifying the overall sealing requirements.
2Object-affected harmful factors
If automated engagement and disengagement of build module is implemented, then operator exposure to starting material is reduced, but device complexity increases
Solution Approach 1:
The build module is equipped with self-aligning engagement features including guide rails, positioning pins, and interlocking mechanisms that enable automated coupling and decoupling with the processing chamber without requiring complex robotic manipulation or precise manual alignment.
Solution Approach 2:
Magnetic coupling mechanisms are used to replace complex mechanical fastening systems for the engagement between build module and processing chamber. The magnetic attraction provides secure holding force while allowing for simple approach and separation, reducing the complexity of automated handling.
3Adaptability or versatility
If separate controllers are used for build module and processing chamber, then operational flexibility is improved, but control system complexity increases
Solution Approach 1:
Each controller is designed with a standardized interface and protocol that allows it to perform multiple functions: controlling atmosphere parameters, managing module engagement, coordinating printing operations, and monitoring system status. This universal design reduces the need for specialized control circuits for each function.
Solution Approach 2:
The controllers are equipped with sensors that continuously monitor atmosphere composition, pressure, and module engagement status. This feedback allows the controllers to automatically adjust their operations and coordinate with each other, simplifying the control logic despite having separate control units.
4Productivity
If continuous printing is enabled with minimal intervention, then productivity increases, but reliability requirements increase
Solution Approach 1:
The system allows the build module to remain sealed and maintain inert atmosphere throughout the entire printing process without requiring opening or intervention. Multiple build modules can be sequentially engaged with the processing chamber, enabling continuous production while each module operates independently and reliably.
Solution Approach 2:
Redundant atmosphere control systems and pre-programmed error handling routines are built into the controllers to anticipate and respond to potential failures before they affect printing quality. The system can automatically detect anomalies and take corrective action without operator intervention.
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 approach minimizes exposure to reactive atmospheric components, ensuring high-quality 3D object production with reduced material degradation and increased operational efficiency, enabling continuous printing with minimal operator intervention and maintaining a controlled atmosphere throughout the printing process.
Implementation Method 1
The build module may comprise a first conditioned atmosphere. The processing chamber may comprise a second conditioned atmosphere.
Implementation Method 2
engaging a build module with a processing chamber, wherein the build module comprises a platform, wherein the build module is controlled by a first controller
Implementation Method 3
printing a 3D object according to a 3D printing method by using the second controller, which 3D object is disposed adjacent to the platform and in the build module
Implementation Method 4
a first layer of hardened material is formed (e.g., by welding powder), and thereafter successive layers of hardened material are added one by one
Implementation Method 5
The build module may be reversibly sealable by a first shutter. The processing chamber may be reversibly sealable by a second shutter.
Implementation Method 6
A load lock volume can be formed in operation (b) between the build module and the processing chamber.
Data Source
AI summary
The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for the production of at least one desired 3D object. The 3D printer system (e.g., comprising a processing chamber, build module, or an unpacking station) described herein may retain a desired (e.g., inert) atmosphere around the material bed and/or 3D object at multiple 3D printing stages. The 3D printer described herein comprises one or more build modules that may have a controller separate from the controller of the processing chamber. The 3D printer described herein comprises a platform that may be automatically constructed. The invention(s) described herein may allow the 3D printing process to occur for a long time without operator intervention and/or down time.