Depowdering Additive Manufacturing Parts with Vortex Vibration

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Solution Overview

Problem

The process of removing loose, unbound powder material from additively manufactured objects, particularly those with small and complex internal geometries, is challenging and time-consuming due to difficulties in accessing these areas.

Innovation Solution

A method involving the application of pressurized fluid and vortex vibration to remove unbound powder material from additively manufactured objects. The method includes applying pressurized fluid to loosen and remove powder, followed by vortex vibration to further loosen remaining powder, with repeated cycles until a specified amount is removed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional depowdering methods are used on objects with small and complex internal geometries, then complete powder removal is difficult to achieve, but the process becomes extremely time-consuming and challenging

Engineering Contradiction:

Improvepowder removal completenessVSAvoiddepowdering process time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies mechanical vibration through a vibratory table or vibratory conveyor to agitate the object and facilitate powder removal from complex internal geometries. The vibration loosens trapped powder particles, enabling more complete removal without requiring manual intervention in difficult-to-access areas, thus reducing overall process time while improving removal completeness.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent uses pressurized air (pneumatics) to blow loose powder out of small and complex internal geometries. Compressed air is directed through or across the object to force powder particles out of inaccessible areas, achieving complete powder removal without extending the depowdering process time significantly.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of manufacture

If binder jetting is used for additive manufacturing, then support structures are not needed and material usage is reduced, but the depowdering process becomes more challenging

Engineering Contradiction:

Improveadditive manufacturing simplicityVSAvoiddepowdering difficulty

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Mechanical vibration is applied to the object during or after the binder jetting process to loosen and remove excess powder from complex geometries. This automated vibration-based approach simplifies the depowdering operation compared to manual methods, maintaining the ease of manufacture benefits of binder jetting while reducing depowdering difficulty.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

Pressurized air systems are used to automatically remove loose powder from objects produced by binder jetting. The pneumatic system directs compressed air through complex internal geometries to eject trapped powder, making the depowdering process easier to operate without requiring support structures or excessive manual intervention.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 effectively removes unbound powder material from both external and internal surfaces of objects with complex geometries, significantly improving the efficiency of the depowdering process.

Implementation Method 1

applying a pressurized fluid to the object via a pressurized fluid applicator operatively coupled to the object, thereby removing a portion of unbound powder material on or in the object

Methodology Applied

Scientific EffectPressurized fluid flow: Fluid Spray

Implementation Method 2

applying vortex vibration to the object via a vortex vibration source operatively coupled to the object, thereby loosening a portion of the unbound powder material remaining on or in the object

Methodology Applied

Scientific EffectVortex vibration: Vibration

Data Source

PatentUS12208573B2Depowdering of additively manufactured objects with small and/or complex internal geometries

Publication Date: 2025.01.28 UCHICAGO ARGONNE LLC

AI summary

A method of depowdering objects (e.g., heat exchangers) having small and/or complex internal geometries and manufactured using an additive manufacturing technique performed with a powder material. The method includes applying a pressurized fluid to the objects via a pressurized fluid applicator operatively coupled to the object, thereby removing a portion of unbound powder material on or in the object. The method further includes applying vortex vibration to the object via a vortex vibration source operatively coupled to the object, thereby loosening a portion of the unbound powder material remaining on or in the object, and applying the pressurized fluid to the object via the pressurized fluid application, thereby removing a portion of the loosened, unbound powder material from the object. The latter two applying steps are repeated until a specified amount of the unbound powder material has been removed from the object.