Build Assembly Rotation for Trapped Powder Removal in 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems face challenges in effectively removing trapped powder material from small or microscopically small cavities within components, often requiring costly auxiliary equipment and leading to waste and increased manufacturing costs.
Innovation Solution
An additive manufacturing system with a rotator assembly that includes a frame, carriage, and drive assembly, allowing the build assembly to be rotated within the housing, enabling trapped powder to be released and collected for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If tubing is inserted through portions of a component to supply air pressure for removing material from cavities, then material removal from accessible cavities is improved, but material trapped within small or microscopically small cavities remains difficult to access and remove
Solution Approach 1:
The system employs a rotatable build assembly that can be dynamically repositioned between a build orientation and an inverted orientation. This dynamic repositioning allows gravity to assist in removing trapped powder from cavities that are difficult to access, complementing the air pressure method for cavities that are more accessible.
Solution Approach 2:
The invention introduces a rotational dimension to the material removal process. By rotating the build assembly from its standard build orientation to an inverted orientation, the system creates a new dimensional approach that enables powder removal through gravity-assisted flow, in addition to the traditional air pressure approach.
2Loss of substance
If auxiliary accessories are used to remove material from smaller cavities, then material removal effectiveness is improved, but manufacturing cost increases and equipment complexity increases
Solution Approach 1:
The rotatable build assembly serves multiple functions: it performs the primary additive manufacturing process in the build orientation, and then can be rotated to an inverted orientation to facilitate powder removal from cavities. This multi-functionality eliminates the need for separate auxiliary equipment, reducing both device complexity and manufacturing cost while maintaining effective material removal.
3Loss of substance
If auxiliary accessories are used to remove material from smaller cavities, then material removal effectiveness is improved, but waste increases and manufacturing cost increases
Solution Approach 1:
The system facilitates the recovery of trapped powder material by inverting the build assembly, allowing gravity to cause the powder to flow out of cavities and be collected. This recovery process reduces waste and eliminates the need for expensive auxiliary removal equipment, thereby reducing manufacturing costs.
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 system improves component fabrication by reducing waste and the need for expensive auxiliary equipment, while effectively recovering trapped powder for reuse in subsequent cycles.
Implementation Method 1
a drive assembly coupled to the carriage for selectively rotating the carriage about a rotational axis that is generally perpendicular to the build direction
Implementation Method 2
a lift assembly coupled to the rotator assembly. The lift assembly is operable to move the rotator assembly within the housing in a direction that is generally parallel to the build direction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An additive manufacturing system (10) includes an additive manufacturing unit (103) that includes a housing (105) for additively processing a powder material (108) along a build direction into a build assembly (130). The additive manufacturing system (10) further includes a rotator assembly (136) for rotating the build assembly (130) within the housing (105). The rotator assembly (136) includes a frame (140) including a first frame arm and a second frame arm and a carriage (150) rotatably coupled to the first frame arm and to the second frame arm The carriage (150) includes at least one coupling mechanism for removably coupling the carriage (150) to the build assembly (130). The rotator assembly (136) further includes a drive assembly (142) coupled to the carriage (150) for selectively rotating the carriage (150) about a rotational axis that is generally perpendicular to the build direction.