Additive Manufacturing Cylinder Wall Extension

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Solution Overview

Problem

Existing additive layer construction methods for producing three-dimensional workpieces face challenges with the vertical mobility of carriers, which can lead to load limits and deviations in layer thickness due to changing weights and non-constant adjustment paths, limiting the maximum volume and complexity of workpieces that can be produced.

Innovation Solution

A device with a vertically movable irradiation unit and a building cylinder wall that can be extended vertically, allowing for increased height and lateral delimitation of raw material powder, enabling the production of larger workpieces without the need for complex and expensive lifting mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the carrier is lowered vertically layer by layer to increase workpiece volume, then the maximum volume of the workpiece increases, but the lifting mechanism reaches load limits and requires more complex and expensive design

Engineering Contradiction:

Improvemaximum volume of workpieceVSAvoidcomplexity of lifting mechanism

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

Instead of moving the carrier vertically to increase workpiece volume, the patent inverts the approach by keeping the carrier stationary and moving the irradiation unit and building cylinder vertically. This reverses which component bears the load, eliminating the need for a complex lifting mechanism while achieving the same goal of producing larger workpieces.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts the lifting function from the carrier and transfers it to the irradiation unit and building cylinder assembly. By separating these functions, the carrier remains stationary and does not need to support the increasing weight, while the irradiation system performs the vertical movement to accommodate growing workpieces.

Inventive Principle:

Principle #2Taking out (Extraction)

2Length of stationary object

If the carrier is lowered vertically to produce larger workpieces, then the height of the building cylinder increases, but the adjustment path becomes non-constant resulting in deviations in layer thickness

Engineering Contradiction:

Improveheight of building cylinderVSAvoidlayer thickness consistency

Core Design Contradiction:

Length of stationary objectVSManufacturing precision

Solution Approach 1:

The patent inverts which component performs the vertical movement: instead of the carrier moving down, the irradiation unit and building cylinder move up relative to the stationary carrier. This inversion maintains a constant adjustment path because the relative positioning system is designed to preserve consistent layer thickness regardless of the absolute height.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent implements feedback control through the control unit that monitors and adjusts the vertical positioning of the irradiation unit and building cylinder. This feedback mechanism ensures that layer thickness remains constant by compensating for any variations in the vertical movement, maintaining manufacturing precision even as the building cylinder height increases.

Inventive Principle:

Principle #23Feedback

3Weight of moving object

If a stationary carrier is used with a vertically movable irradiation unit, then the load on the lifting mechanism is reduced, but the building cylinder wall must be extendable vertically adding structural complexity

Engineering Contradiction:

Improveload on lifting mechanismVSAvoidextendability of building cylinder wall

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The building cylinder wall is segmented into multiple extendable sections that can be vertically assembled or telescoped. This segmentation allows the wall to grow in height as needed without requiring a single complex movable structure, distributing the structural complexity across modular segments while keeping the carrier stationary and lightweight.

Inventive Principle:

Principle #1Segmentation

4Length of moving object

If the carrier moves vertically to accommodate larger workpieces, then the maximum height of workpiece increases, but the changing weight leads to non-constant adjustment paths

Engineering Contradiction:

Improveheight of workpieceVSAvoidconstant adjustment path

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The patent inverts the vertical movement assignment: the carrier remains stationary while the irradiation unit and building cylinder perform the vertical movement. This inversion decouples the workpiece height increase from carrier movement, allowing the adjustment path to remain constant because the positioning system is designed around the stationary carrier reference point.

Inventive Principle:

Principle #13The other way round (Inversion)

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 solution allows for the production of larger and more complex three-dimensional workpieces by maintaining consistent layer thickness and reducing the load on the lifting mechanism, enabling the creation of workpieces with theoretically infinite height within a compact device.

Implementation Method 1

The irradiation unit (23) is configured to selectively irradiate the raw material powder (9) applied to the carrier (3) with electromagnetic radiation or particle radiation in order to solidify the irradiated raw material powder

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Heating

Implementation Method 2

The laser radiation penetrates into the raw material powder material and solidifies it, for example as a result of heating, causing melting or sintering

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

a vertical movement device which is configured to move the irradiation unit (23) vertically with respect to the carrier (3)

Methodology Applied

Scientific EffectMechanical vertical movement:

Implementation Method 4

a building cylinder wall (11) which extends substantially vertically and which represents a lateral boundary for the raw material powder (9) applied to the carrier (3), the building cylinder wall (11) being configured to increase its vertical height during a building process

Methodology Applied

Scientific EffectVertical expansion of building cylinder:

Data Source

PatentEP3624966B1Device and method for producing three-dimensional workpieces

Publication Date: 2021.12.22 NIKON SLM SOLUTIONS AG

Figure 1a~1b
Figure 2a~2b
Figure 3a~3b

AI summary

The invention relates to a device for producing three-dimensional workpieces. The device comprises a carrier for receiving raw material powder and a radiation unit for selectively radiating the raw material powder applied to the carrier with electromagnetic radiation or particle radiation in order to produce on the carrier a workpiece made of the raw material powder by a generative layering construction process. The device also comprises a vertical movement means, which is designed to move the radiation unit vertically relative to the carrier, and a cylinder construction wall, which extends substantially vertically and which constitutes a lateral delimitation for the raw material powder applied to the carrier, wherein the cylinder construction wall is designed to increase its vertical height during the construction process.