Discharging Device for Layered Particulate Material

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Solution Overview

Problem

Existing 3D printing technologies face challenges with complex and costly 'intelligent' discharging devices for precise control of particulate material, leading to material wastage and unsteady coating processes, especially when using 'unintelligent' discharging devices that lack dosing control and result in material loss beyond the build space.

Innovation Solution

A method and device where a vertically adjustable body simulates a discharged layer to close the discharge opening at the edge of the build space, preventing material loss and allowing unused material to be collected and reused, using a simple, non-switchable, displacement-controlled discharging device, which is cost-effective and maintains high coating quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If an 'unintelligent' discharging device without dosing control is used, then device complexity is reduced and cost is decreased, but material loss increases and coating process becomes unsteady

Engineering Contradiction:

Improvedischarging device structureVSAvoidparticulate material loss

Core Design Contradiction:

Device complexityVSLoss of substance

Solution Approach 1:

A vertically adjustable body is introduced as an intermediary element between the discharging device and the build platform. This body simulates a discharged layer and closes the discharge opening at the build space edge, preventing material loss without requiring complex dosing control mechanisms in the discharging device itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The vertically adjustable body creates a simulated or copied layer structure that mimics the appearance and function of an actual discharged particulate material layer. This copy serves to close the discharge opening and prevent material loss without requiring the discharging device to have intelligent dosing capabilities.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If a build platform is lowered vertically into the build container, then larger three-dimensional moldings can be produced, but technical complexity increases due to sealing requirements

Engineering Contradiction:

Improvebuild space sizeVSAvoidbuild container sealing

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of lowering the build platform into the build container, the invention inverts the approach by keeping the build platform stationary and raising the discharging device and print head relative to it. This eliminates the need for complex sealing mechanisms while still enabling the production of larger three-dimensional moldings.

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If the build platform is lowered by more than one layer thickness, then larger moldings can be constructed, but friction forces and stresses on guides and drives increase

Engineering Contradiction:

Improvemolding heightVSAvoidfriction forces on guides

Core Design Contradiction:

ProductivityVSForce

Solution Approach 1:

The invention inverts the conventional approach by keeping the build platform stationary and moving the discharging device vertically instead. This eliminates the need to overcome friction forces between the build platform and build container wall, while still enabling the construction of larger moldings by raising the discharging device to appropriate heights.

Inventive Principle:

Principle #13The other way round (Inversion)

4Adaptability or versatility

If a vertically moving build platform is used, then larger moldings can be produced, but high stresses occur on guides and drives during reversing operations

Engineering Contradiction:

Improvemolding sizeVSAvoidstresses on guides and drives

Core Design Contradiction:

Adaptability or versatilityVSStress or pressure

Solution Approach 1:

The invention transfers the vertical movement from the build platform to the discharging device and print head. This inversion eliminates the high stresses on guides and drives that occur during reversing operations of a vertically moving build platform, while still enabling the production of larger moldings through controlled vertical movement of the discharging device.

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 approach allows for variable and material-saving adjustment of the build space size, reducing material loss and operational costs while maintaining high coating quality, even with 'unintelligent' discharging devices, by preventing material discharge beyond the build space edges and enabling the reuse of excess material.

Implementation Method 1

the layers being solidified and joined together in locally predetermined areas by the action of a binder

Methodology Applied

Scientific EffectBinder action: Adhesive

Data Source

PatentUS11407216B2Device and method for constructing a layer body

Publication Date: 2022.08.09 VOXELJET AG

AI summary

The invention relates to a device for constructing a laminar body from a plurality of superimposed layers of free-flowing material, in particular particulate material, and a build platform within a working area. The layers are solidified in locally predetermined regions by the action of binders and are joined together so that at least one moulded body is formed by the solidified and joined regions of the layers. The device comprises a discharging device movable back and forth over the working area in at least one discharge direction and having at least one discharge opening from which the free-flowing material can be discharged in individual superimposed layers during the movement of the discharging device.