Build Platform Surface Patterning for Uniform Powder Bed Deposition
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Solution Overview
Problem
Existing additive manufacturing by powder bed deposition methods require sandblasting or machining to achieve a uniformly distributed first layer of powder on the build platform, which necessitates the use of specialized machines and consumables, increasing costs and preparation time.
Innovation Solution
A method to prepare the build platform by imprinting a pattern using the same energy source used for melting, such as a laser beam, to create a grid or cellular pattern that increases the surface roughness, allowing for uniform powder distribution without the need for external machines or consumables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sandblasting or machining is used to increase surface roughness, then powder distribution quality is improved, but equipment complexity and consumable costs increase
Solution Approach 1:
The patent replaces mechanical sandblasting or machining systems with a laser beam system to create surface roughness. The laser beam melts and redistributes material on the build platform surface, creating a patterned rough surface that improves powder adhesion without requiring external mechanical preparation equipment or consumables.
Solution Approach 2:
The laser beam system performs dual functions: it both prepares the build platform surface by creating roughness patterns and subsequently melts the powder layers during additive manufacturing. This eliminates the need for separate surface preparation equipment and integrates the preparation function into the existing manufacturing system.
2Reliability
If sandblasting or machining is used to increase surface roughness, then powder adhesion is improved, but preparation time and cost increase
Solution Approach 1:
The patent combines the surface preparation step with the additive manufacturing process by using the same laser beam for both purposes. The laser creates the roughness pattern on the build platform before powder deposition, ensuring good powder adhesion, and then the same laser system melts the powder layers, eliminating the need for separate preparation and manufacturing phases.
Solution Approach 2:
The build platform surface is prepared using the laser beam that is already part of the additive manufacturing system. The system prepares its own working surface without requiring external preparation equipment or additional consumables, making the process self-sufficient and reducing both time and cost.
3Shape
If external machines and consumables are used for surface preparation, then surface roughness is achieved, but process simplicity is reduced
Solution Approach 1:
The patent replaces complex mechanical surface preparation systems (sandblasting equipment, machining centers) with a laser beam system that is already integral to the additive manufacturing machine. The laser creates the desired surface roughness through selective melting and redistribution of material, eliminating the need for external mechanical preparation equipment and simplifying the overall process.
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 method reduces preparation costs and time by creating a pattern directly within the additive manufacturing machine, ensuring a uniformly distributed and adhered first layer of powder, enhancing the metallurgical bond between the build platform and the manufactured items.
Implementation Method 1
the imprinting of the pattern is done inside the machine for additive manufacturing by powder bed deposition in which the build platform is subsequently used for additive manufacturing by powder bed deposition, the imprinting of the pattern being done before a layer of powder is spread over the build platform. Advantageously, the preparation method provides that the pattern is imprinted onto the upper surface of the build platform with the same source of energy or of heat which is subsequently used to selectively melt the powder, this source preferably being a source emitting at least one laser beam.
Implementation Method 2
powder-based additive manufacturing by melting grains of this powder with the aid of one or more sources of energy or of heat, such as a laser beam and/or a beam of electrons and/or diodes
Data Source
AI summary
Method for preparing the upper surface of a build platform for additive manufacturing by powder bed deposition, the method comprises at least one step of increasing the roughness of at least one region of the upper surface of the build platform by imprinting a pattern onto this region. The imprinting of the pattern is done inside the machine for additive manufacturing by powder bed deposition in which the build platform is subsequently used for additive manufacturing by powder bed deposition.