Additive Manufacturing Powder Recovery With Rate-Controlled Separation
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in achieving a high manufacturing output due to the impact of a large extraction rate of powdered material on downstream processes, leading to potential clogging and reduced efficiency.
Innovation Solution
Implementing a controlling device to manage the extraction and separation rates of powdered material, ensuring they remain below predetermined thresholds to avoid affecting downstream processes, allowing for a high extraction rate while maintaining apparatus performance and enabling rapid material reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a relative large extraction rate of powdered material is used, then the time period for extracting material is reduced and manufacturing output is improved, but the performance of downstream separating processes is negatively affected
Solution Approach 1:
The extraction device operates with variable extraction rates that are dynamically adjusted based on real-time monitoring of the separating device's performance and the current state of the powdered material processing, allowing the system to optimize between high productivity and reliable separation
Solution Approach 2:
A control system continuously monitors the extraction rate and the performance of the separating device, using this feedback information to adjust the extraction rate dynamically, ensuring that the separating process remains effective while maintaining high manufacturing output
2Loss of time
If a relative large extraction rate is used, then material reuse time is reduced, but the volume of powdered material that must be stored increases
Solution Approach 1:
The system prepares and pre-processes powdered material in advance through efficient separation and filtering mechanisms, so that material is ready for reuse immediately after extraction without requiring large storage volumes for aging or stabilization
Solution Approach 2:
The separating device efficiently recovers and filters powdered material during the extraction process itself, enabling immediate reuse of separated material without requiring large storage volumes, thus reducing both storage requirements and material loss time
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 enables a high manufacturing output by minimizing process interruptions and reducing the need for large material storage volumes, facilitating efficient and continuous operation.
Implementation Method 1
an extraction device for fluid flow connected to said process chamber and arranged for extracting powdered material originating from said bath of powdered material
Implementation Method 2
a separating device for realising a separation rate of filtering and/or sieving said powdered material originating from said bath of powdered material
Implementation Method 3
a separating device for realising a separation rate of filtering and/or sieving said powdered material originating from said bath of powdered material
Implementation Method 4
a solidifying device for solidifying a selective layer-part of said material on said surface level
Data Source
AI summary
An additive manufacturing method including the steps of receiving a bath of powdered material having a surface level defining an object working area, solidifying a selective layer-part of the bath of powdered material on the surface level, extracting powdered material originating from the bath of powdered material, and controlling at least one of an extraction rate of an extraction device for extracting powdered material originating from the bath of powdered material, and a separation rate of a separation device configured to filter and/or sieve powdered material originating from the bath of powdered material.