Additive Manufacturing Build Plate Homing for Solidification Accuracy
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Solution Overview
Problem
In additive manufacturing, particularly for metal objects, achieving a desired accuracy and reducing the variation in force required to separate the object from the build plate is challenging due to inconsistencies in the solidification process.
Innovation Solution
The apparatus includes a process chamber with a support for the build plate, a solidifying device, and a homing device that adjusts the build surface's height and tilts it to maintain a constant surface level, using a detection device and powder removing/addition mechanisms to ensure accurate positioning and minimize separation force variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the build surface height is not accurately controlled, then the manufacturing process is simpler, but the solidification accuracy and separation force variation increase
Solution Approach 1:
The homing device performs preliminary positioning of the build surface to a known home position before manufacturing begins. This preliminary action establishes a reference height, and the detection device continuously monitors the build surface height relative to this reference, enabling accurate height control without complex real-time adjustment mechanisms during manufacturing.
Solution Approach 2:
The detection device provides continuous feedback on the build surface height by detecting the position of the build surface relative to the bath surface. This feedback is used to control the support device, which adjusts the build surface height to maintain consistency. The closed-loop feedback system ensures manufacturing precision without requiring overly complex mechanical height control mechanisms.
2Reliability
If the build surface height varies, then the apparatus structure is simpler, but the separation force variation increases causing object damage
Solution Approach 1:
The detection device continuously monitors the build surface height and provides feedback to the support device. This feedback control maintains a substantially constant build surface height throughout the manufacturing process, ensuring uniform solidification conditions and consistent separation forces, thereby preventing object damage during removal.
Solution Approach 2:
The system dynamically adjusts the build surface height parameter by controlling the support device to maintain a constant height. This parameter control ensures that the solidification process occurs under consistent conditions, leading to uniform bonding strength and reduced variation in separation force, which protects object integrity during removal.
3Manufacturing precision
If the bath surface level is not maintained, then the apparatus is simpler, but the manufacturing accuracy decreases
Solution Approach 1:
The detection device monitors both the build surface height and the bath surface level. When the bath surface level deviates from the desired position, the system activates the powder removing device or layering device to adjust the bath level. This feedback control maintains consistent layer thickness and solidification accuracy without requiring complex mechanical bath level maintenance mechanisms.
Solution Approach 2:
The powder removing device removes excess powder from the bath surface when the level is too high, and the layering device adds powder when the level is too low. This dynamic adjustment of material (discarding and recovering powder) maintains a substantially constant bath surface level, ensuring manufacturing precision while avoiding complex mechanical level control systems.
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 enhances the accuracy of solidification and reduces the variation in separation force, minimizing the risk of damaging the object during removal and maintaining a consistent surface level for precise manufacturing.
Implementation Method 1
A solidifying device, such as a laser device, for solidifying a layer of the material on the surface, in particular by means of electromagnetic radiation
Implementation Method 2
a detection device for detecting a build surface and for detecting pre-determined images of a surface level of the bath of powdered material on the build surface
Data Source
Figure 1
AI summary
Apparatus for producing an object by means of additive manufacturing, comprising: a process chamber for receiving on a build surface of a build plate a bath of powdered material which can be solidified; a support for positioning said build plate in relation to a surface level of said bath of powdered material in said process chamber; a solidifying device for solidifying a selective part of said material; and a homing device for moving said build surface, by said support, to a home position. Method of producing an object by means of additive manufacturing on a build surface of a build plate.