3D Printing Coater Edge Powder Control
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Solution Overview
Problem
Existing methods for producing three-dimensional objects through layering and selective solidification of powdery building materials face limitations in controlling the application of powder within the construction area, leading to issues like clumped powder being carried over from the edge area into the construction area, which affects the quality and precision of the manufactured components.
Innovation Solution
A method and device that actively control the application of powdery building material by reducing or eliminating its application in edge areas, using a coater with a metering device and controlled closure to limit powder distribution within the designated coating area, and optionally heating the worktop or worktable to prevent clumping and improve temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coater applies powder over the entire working plane including edge areas, then the build area is adequately supplied with powder, but clumped powder is carried from the edge area into the construction area affecting quality
Solution Approach 1:
The patent applies local quality by differentiating the treatment of edge areas from build areas. The coater is controlled to apply reduced or no powder in edge areas while maintaining full powder application in build areas. This localized differentiation prevents clumped powder formation at edges while ensuring adequate powder supply in construction zones, thereby eliminating contamination without compromising manufacturing precision
2Manufacturing precision
If the coater moves across the entire working plane to apply powder, then complete coverage is achieved, but application conditions become inconsistent and temperature disruptions occur
Solution Approach 1:
The patent implements local quality by spatially differentiating powder application based on functional zones. Build areas receive full powder application under controlled conditions, while edge areas receive reduced or no powder. This localized approach ensures consistent application conditions in construction zones and prevents temperature disruptions that would occur from heating large edge areas
Solution Approach 2:
The patent applies preliminary anti-action by proactively preventing clumped powder formation through controlled reduction of powder application in edge areas before the coater completes its traverse. By anticipating and preventing the harmful effect of clumping in edge zones, the system maintains temperature uniformity and application consistency in the build areas
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 ensures precise application of powder only where needed, preventing clumped powder from entering the construction area, thereby enhancing the quality and precision of the three-dimensional objects produced by maintaining consistent application conditions and reducing temperature-related disruptions.
Implementation Method 1
applying a layer of the powdered build-up material in the working plane by means of a coater moving over the working plane
Implementation Method 2
selectively solidifying the applied powder layer at locations corresponding to a cross-section of the object to be produced
Implementation Method 3
optionally heating the worktop or worktable to prevent clumping and improve temperature distribution
Data Source
Figure 1
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Figure 4
AI summary
A method for producing a three-dimensional object (2) on a support (7, 8, 9) by layered application and selective compaction of a powdered buildup material (13) comprises the steps of: lowering the support (7, 8, 9) to a predetermined height above a working plane (10), applying a layer (31) of the powdered buildup material (13) in the working plane (10) by means of a coater (14) travelling over the working plane (10), selectively compacting the applied powder layer (31) at places that correspond to a cross section of the object (2) to be produced, and repeating the steps of lowering, applying and selectively compacting until the object (2) is completed. Within an intended coating region (B) lying in the working plane (10), the amount of powdered buildup material (13) that is applied with respect to at least one powder layer is reduced in an actively controlled manner in certain portions in a region that is travelled over by the coater (14) or no powdered buildup material (13) at all is applied.