Continuous Powder Bed Fusion on a Circular-Ring Platform
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Solution Overview
Problem
The time-consuming nature of additive manufacturing processes due to the layer-by-layer approach, which is slower compared to traditional subtractive manufacturing methods.
Innovation Solution
A continuous method for additive manufacturing involving a build platform with a circular ring-shaped upper surface that moves downwards, combined with simultaneous actions of a printing material dispenser, recoater, and fusing device, executing deposition, leveling, and fusion continuously until the component is manufactured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional layer-by-layer additive manufacturing is used, then manufacturing precision and design flexibility are improved, but production time increases significantly
Solution Approach 1:
The patent implements continuous additive manufacturing where the build platform rotates continuously during the entire printing process rather than moving step-by-step. The printing head deposits material continuously along spiral or circular paths while the platform rotates, eliminating the need for repeated deceleration, positioning, and acceleration cycles. This continuous motion maintains constant material deposition and fusion operations, significantly reducing production time while preserving layer-by-layer manufacturing precision through controlled material extrusion and curing.
2Reliability
If traditional sequential processing steps are used, then process control and quality are improved, but manufacturing speed decreases
Solution Approach 1:
The patent merges multiple sequential processing steps into a single continuous operation. The deposition of material and its subsequent fusion (curing) occur simultaneously in a continuous workflow rather than as separate sequential steps. The build platform rotation, material extrusion, and UV curing all happen concurrently, with the platform rotating continuously while the printing head deposits and cures material in real-time. This integration eliminates idle time between steps and maintains constant production velocity.
3Adaptability or versatility
If traditional additive manufacturing methods are used, then design flexibility and complexity are improved, but time consumption increases
Solution Approach 1:
The patent employs dynamic motion control where the build platform rotates continuously at variable speeds and the printing head moves dynamically to deposit material along complex spiral or circular trajectories. This dynamic approach allows intricate three-dimensional designs to be created through continuous motion paths rather than sequential layer stacking. The system can adapt the rotation speed and deposition rate in real-time to match the geometric complexity of the design, maintaining design flexibility while eliminating the time-consuming pause-and-go nature of traditional methods.
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
Optimizes the additive manufacturing process by increasing efficiency and consistency, allowing for rapid production of intricate components with improved material distribution and reduced time consumption.
Implementation Method 1
a fusing device (18), wherein the fusing device (18) is configured to fuse the printing material (20)
Data Source
Figure 1~2
Figure 3
AI summary
A continuous method (100) for additive manufacturing, preferably powder bed fusion, a component (50), the method (100) comprising the following steps: (S1) Providing at least one build platform (10), wherein the at least one build platform comprises (10) a circular ring-shaped upper surface (12) and is configured to continuously move downwards, (S2) Providing a printing material dispenser (14) and a recoater (16), wherein the printing material dispenser (14) and the recoater (16) are configured to move relatively to the at least one build platform (10), (53) Providing a fusing device (18), wherein the fusing device (18) is configured to fuse the printing material, (S4) Depositing, via the printing material dispenser (14), printing material (20) on the circular ring-shaped upper surface (12) of the at least one build platform (10), while moving the printing material dispenser (14) relatively to the at least one build platform (10), (S5) Leveling, via the recoater (16), the printing material (20) on the circular ring-shaped upper surface (12), while moving the recoater (16) relatively to the at least one build platform (10), (S6) Fusing, via the fusing device (18), the printing material (20), while moving the fusing device (18) relatively to the at least one build platform (10), (S7) Moving downwards the at least one build platform (10), wherein the steps of depositing, leveling, fusing and moving downwards are executed simultaneously and continuously, until the component (50) is manufactured, (S8) Taking out the component (50).