De-Powdering Basket for Additive Manufacturing
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Solution Overview
Problem
Current de-powdering techniques for 3D printed parts in powder bed fabrication, such as vacuuming and manual removal, are inefficient and can damage the soft, unhardened parts, with vacuum methods causing filter blockages and manual methods being labor-intensive and risky.
Innovation Solution
A de-powdering basket with perforated side walls and a build plate that forms a liner within the build box, allowing loose powder to escape under gravity or with assistance from vibrations and air jets, while the basket's design prevents powder leakage during printing and facilitates safe removal of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuuming is used to remove excess powder, then powder removal efficiency is improved, but filter blockage occurs and smaller particles are separated
Solution Approach 1:
The harmful function of vacuuming (filter blockage) is extracted and replaced by a different mechanism. The patent uses a de-powdering basket with perforated walls that allows gravity-driven powder removal without vacuum, eliminating the filter blockage problem while maintaining powder removal efficiency
Solution Approach 2:
The de-powdering basket acts as an intermediary device between the printed part and the build box. It provides a controlled environment for powder removal through its perforated structure, allowing excess powder to escape while protecting the part and avoiding direct vacuum contact
2Ease of operation
If manual hand tools are used to remove excess powder, then labor intensity is reduced, but part damage risk increases
Solution Approach 1:
The system enables self-service powder removal where the de-powdering basket automatically allows excess powder to escape through its perforated walls using gravity and vibrations, eliminating the need for manual intervention and thereby reducing both labor intensity and part damage risk
Solution Approach 2:
Vibrations are applied to the de-powdering basket to facilitate powder removal through the perforated walls. This mechanical vibration mechanism efficiently removes excess powder without requiring manual hand tools, thus reducing labor intensity while preventing part damage
3Productivity
If de-powdering basket with apertures is used, then powder removal is facilitated, but powder leakage during printing may occur
Solution Approach 1:
The de-powdering basket incorporates a dynamic sealing mechanism where the build plate can be lowered to seal against the basket walls during printing, preventing powder leakage. After printing, the seal is released to allow powder removal through the apertures, thus achieving both goals dynamically
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
The de-powdering basket efficiently removes excess powder without damaging the parts, reducing the risk of damage and labor, and allows for safer handling and processing of 3D printed parts before sintering.
Implementation Method 1
loose powder to escape under the force of gravity
Implementation Method 2
vibrations may be applied to the de-powdering basket to dislodge the loose powder
Implementation Method 3
air jets or fluid (e.g., water) jets may be used instead of or in addition to vibrations to encourage the egress of the loose powder
Data Source
AI summary
A de-powdering basket comprises an enclosure of at least one side wall and a bottom wall. The enclosure is configured such that, when the enclosure is disposed within a build box, the outer surfaces of the at least one side wall are substantially adjacent to the interior walls of the build box. The enclosure further comprises one or more apertures disposed within the at least one side wall, each of the apertures comprising a void that extends through the at least one side wall from an interior surface of the side wall to an exterior surface of the side wall. The enclosure may be configured to accommodate a build plate situated within the enclosure. Outer edges of the build plate may cooperate with inner surfaces of the side walls of the enclosure to prevent loose powder from passing between the outer edges of the build plate and the side walls.