Continuous Metal Powder Additive Production for Series Manufacturing
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Solution Overview
Problem
Conventional additive production methods, such as selective laser sintering and fused deposition modeling, are not suitable for series production due to the need to stop and clean the powder bed after each component is produced, limiting their efficiency and applicability to only individual prototypes.
Innovation Solution
A method involving the application of metal powder in layers on a base member using a laser beam for partial melting and solidification, where the base member is continuously transported away from the construction face, allowing for the production of multiple objects sequentially without stopping the process, and enabling efficient heat dissipation to prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive production methods (selective laser sintering, fused deposition modeling) are used to produce three-dimensional models layer by layer, then individual prototypes can be created with high precision, but series production is not possible due to the need to stop and clean the powder bed after each component
Solution Approach 1:
The construction process is segmented into separate zones: a construction zone where layers are applied and cured, and a removal zone where completed components are detached. This allows simultaneous operation of multiple components in different stages, enabling series production while maintaining precision through zone-specific optimization
Solution Approach 2:
Support structures are pre-formed as part of the construction process, and the platform is preliminarily prepared with release agents or specific surface treatments to facilitate easy component removal. This preliminary preparation eliminates the need for cleaning operations between production cycles
2Ease of manufacture
If the construction platform is lowered downward into a powder bed in the direction of a container base, then layers can be applied sequentially, but the method sequence becomes complicated and requires stopping before producing new components
Solution Approach 1:
The construction platform is oriented horizontally rather than vertically, and layers are applied in a horizontal plane. The transport mechanism moves the platform horizontally through different zones (construction zone to removal zone), transforming the vertical layering process into a horizontal conveyor-style operation that simplifies the method sequence
3Strength
If metal powder is applied in layers and selectively melted by laser beam, then high-strength components can be produced, but heat accumulation causes deformation without efficient heat dissipation
Solution Approach 1:
The completed component is extracted from the construction zone and transported to the removal zone after each layer is formed. This continuous extraction prevents heat accumulation in the finished portion, allowing efficient heat dissipation during transport and maintaining dimensional accuracy while preserving the high strength of laser-melted material
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 enables series production by allowing continuous production without stopping between objects, improving thermal management to prevent deformation, and facilitating the reuse of metal powder, thus enhancing the efficiency and applicability of additive manufacturing beyond individual prototypes.
Implementation Method 1
being partially molten by means of a laser beam
Implementation Method 2
being partially molten by means of a laser beam
Implementation Method 3
improving thermal management to prevent deformation
Data Source
AI summary
The present disclosure provides an additive production method of producing an object by metal powder being applied in a production region in layers by an application device. The metal powder is applied to a base member along a construction face and is partially molten by a laser beam and solidified. A continuous conveyor transports the base member with the object in a transport direction away from the construction face. The continuous conveyor further transports the base member with the completed object to a removal region where the object is removed from the continuous conveyor. Support structures are produced on the object and are connected to the base member. The support structures are removed after the removal region has been reached.