3D Printing Coater Inclined Angle Prevents Particulate Fall
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Solution Overview
Problem
Conventional 3D printing methods face inaccuracies and defects due to particulate material detaching and falling onto the build space, potentially damaging the print head and components, and uncontrollable fluid entry, which limits the production of large components and productivity.
Innovation Solution
A device with a coater and print head arrangement where the coater moves upward at an inclined angle to prevent particulate material from falling, and a system with collecting hoppers and conveyor lines to manage and recycle excess material, ensuring even layer application and preventing collisions, while the print head moves downward at an inclined angle to solidify layers without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coater is moved back over the coated plane after coating operation, then the coating process can be completed, but particulate material detaches and falls onto the build plane causing inaccuracies and defects
Solution Approach 1:
The invention extracts and removes the harmful factor (detached particulate material) from the build space using a suction device with a suction opening positioned in the build space. The suction device actively removes loose particulate material before it can accumulate and cause collisions with the print head, thus maintaining manufacturing precision while allowing continuous coating operations.
Solution Approach 2:
The suction device acts as an intermediary between the coating process and the build space. It mediates by continuously removing excess particulate material during and after the coating operation, preventing material accumulation that would otherwise lead to print head collisions and molded part defects.
2Ease of manufacture
If conventional vertical layer deposition is used, then layers can be applied straightforwardly, but component size is limited and large components must be segmented reducing productivity
Solution Approach 1:
The invention transitions from vertical layer deposition to horizontal layer feed using an endless conveyor belt. This dimensional change allows continuous production of large components in the horizontal direction without segmentation, eliminating the need to remove and reassemble multiple built sections while maintaining straightforward layer application processes.
3Productivity
If horizontal layer feed with continuous conveyor belt is used, then continuous components can be produced with unlimited length, but the angle of layer application must be smaller than the angle of repose of powder material
Solution Approach 1:
The invention changes the operational parameters of the coating process by using a conveyor belt system that moves the build platform horizontally. This allows the build platform to be inclined at an angle smaller than the angle of repose of the powder material, enabling horizontal layer feed while maintaining proper powder flow characteristics and layer deposition quality.
4Ease of manufacture
If fluids are used in the coating process, then coating can be applied effectively, but fluids may enter the build space uncontrollably causing damage
Solution Approach 1:
The suction device also serves to extract and remove excess fluids from the build space, preventing uncontrolled fluid entry that could damage the build platform or molded parts. The suction system maintains proper fluid levels and prevents flooding while allowing effective coating application to continue.
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 arrangement enhances the precision and quality of molded parts by preventing uneven layers and collisions, allowing for the production of larger components without segmentation, and enables automatic startup and recycling of particulate material, thus improving productivity and reducing manual intervention.
Implementation Method 1
Since gravity prevents a layer from being applied perpendicularly to the layer feed, the individual layers are applied spatially at an angle to the perpendicular. The angle is selected in such a way that it is smaller than the specific angle of repose of the corresponding powder material.
Implementation Method 2
a second material, which may form a solid with the first material, is subsequently applied thereupon... a binder material is then selectively printed onto the particulate material using a print head. The particle area onto which the binder is printed sticks together and solidifies under the influence of the binder
Data Source
AI summary
The invention relates to a device for producing three-dimensional models, comprising a coater, which includes an ejection opening, at least one print head, which is mounted on a print axis, the ejection opening of the coater being disposed toward the top in the coating direction, and the print head being disposed counter to the coating direction with the opposite orientation on the printing axis behind the coater in the coating direction; the invention also relates to a method for producing three-dimensional models.