3D Printing Diffuser Plate for In Situ Material Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing systems require additional devices for removing unused build material, increasing costs and complexity, as they do not efficiently manage the in situ removal of uncoalesced material within the build chamber.
Innovation Solution
A 3D printing system with a build platform featuring holes, a diffuser plate, and an airflow channel that allows for in situ removal of unused build material by choking the holes with initial layers, using airflow and vibration to dislodge and collect the material, eliminating the need for external devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional devices are used for removing unused build material, then removal effectiveness is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the build platform and material removal function into a single integrated system. The build platform includes holes that allow unused material to fall through, and the same platform structure serves both as the build surface and as the removal mechanism, eliminating the need for separate removal devices.
Solution Approach 2:
The system uses its own built-in features (holes in the build platform, airflow channels, vibration mechanisms) to perform the material removal function. The build platform itself facilitates removal by allowing material to pass through holes and the vibration mechanism uses the platform's structure to dislodge material, making the system self-sufficient without external devices.
2Device complexity
If in situ removal is implemented within the build chamber, then operational complexity is reduced, but removal efficiency may deteriorate
Solution Approach 1:
The patent implements continuous airflow through the build platform holes throughout the printing process, allowing unused material to be continuously removed and collected in a receptacle. This continuous action maintains efficiency while keeping the system simple, as the removal process occurs simultaneously with printing without requiring separate operational phases.
Solution Approach 2:
The patent uses airflow (pneumatics) to remove unused build material. Air is flowed through the holes in the build platform to dislodge and carry away unused material to a collection receptacle, providing an efficient removal mechanism that is simple to implement and integrates within the existing build chamber structure.
3Productivity
If holes are used for material removal, then removal capability is improved, but manufacturing precision may worsen due to material falling through
Solution Approach 1:
The patent applies a coating layer to the build platform surface before printing. This preliminary coating creates a uniform, controlled surface that prevents build material from adhering excessively to the platform, ensuring consistent material distribution and preventing precision issues while allowing holes to function for material removal.
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
Enables efficient and cost-effective removal of unused build material within the same build chamber, reducing operational complexity and allowing for potential recycling of materials, while maintaining a consistent airflow for uniform removal.
Implementation Method 1
an airflow channel that allows air to be flowed through the build platform and diffuser plate
Implementation Method 2
a vibration device that vibrates the build platform to dislodge the unused build material from the diffuser plate
Data Source
AI summary
A three-dimensional printing system may include a build platform, the build platform including at least one hole defined through the build platform, a diffuser plate placed below the at least one hole to maintain an amount of build material between a lower surface of the build platform and an upper surface of the diffuser plate, and a flow channel defined around the diffuser plate and sealing the diffuser plate from atmosphere.