Build Removal Receptacle With Roller Retention for Hot Powder Transfer
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Solution Overview
Problem
Existing additive manufacturing (AM) processes, such as electron beam melting (EBM), require significant downtime for manual removal of build structures due to the need for cooling and are inefficient with existing removal devices, especially when handling costly and flammable metallic powders like titanium.
Innovation Solution
A build removal tool and receptacle system that allows for the safe and efficient transfer of in-process fused powder build structures from AM machines without direct user contact, using a rotatable frame roller and latching mechanism to retain the build structure and excess powder, along with a removable build plate to reduce machine downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual removal of build structures is used, then user control and flexibility are improved, but downtime increases due to cooling requirements and removal difficulty
Solution Approach 1:
The patent introduces a build removal tool as an intermediary device between the user and the hot build structure. This tool allows users to safely handle and remove build structures immediately after printing without direct contact, eliminating the need to wait for cooling while maintaining user control through the tool's handle and maneuverable design
2Loss of time
If clamping tool with teeth is used to remove build structures, then cooling time is eliminated, but the tool crushes excess powder making removal ineffective and more time-consuming
Solution Approach 1:
The patent employs a flexible bladder-like structure with an expandable balloon element that can be inflated to gently cradle and lift the build structure. This flexible membrane approach allows the tool to adapt to the build structure's shape and size without crushing the delicate excess powder, maintaining removal effectiveness while eliminating cooling time
Solution Approach 2:
The tool uses a balloon element that can be inflated or deflated to change its volume and shape, allowing it to conform to different build structures. This parameter change enables the tool to effectively remove various build structures without crushing powder, solving the productivity issue
3Adaptability or versatility
If collecting box in molding apparatus is used, then build structures can be held during fabrication, but the box is limited to specific machine configurations and exposed to environmental conditions
Solution Approach 1:
The patent introduces a portable build removal tool as an intermediary that can be used with any additive manufacturing machine. This tool is not machine-specific but can be manually applied to remove builds from various machine types, greatly improving adaptability while allowing removal in controlled conditions rather than exposing builds to machine environmental conditions during storage
4Loss of time
If build structures are removed hot, then downtime is reduced, but safety risks increase due to flammable metallic powder
Solution Approach 1:
The patent employs a balloon element that can be inflated with inert gas or air to create a protective atmosphere around the hot build structure during removal. This inert environment prevents combustion of the flammable metallic powder while allowing hot build removal, simultaneously addressing both downtime reduction and safety concerns
Solution Approach 2:
The build removal tool acts as an intermediary barrier between the user and the hot, flammable build structure. By using this tool with a handle and balloon element, users can safely manipulate hot builds without direct contact, reducing safety risks while enabling immediate removal
Data Source
AI summary
A receptacle for use in the retention and transfer of an in-process fused powder build structure from an additive manufacturing machine includes a base and a panel. The base includes a bottom surface. The panel includes a frame and a roller extending from the frame. The frame is attached or attachable to the base such that the panel is moveable between a first position in which a top surface of the roller lies in a first plane parallel to a second plane defined by the bottom surface of the base and a second position in which the panel and the base surround the build structure when the build structure is retained by the receptacle.