Dual Build Material Supply System for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing processes face interruptions due to changes in build material supply devices, particularly when storage units become empty and need to be exchanged or refilled.
Innovation Solution
The implementation of a dual build material supply and application system, where a second build material supply device and application device are used to supply build material to the first supply device, thereby preventing interruptions during the additive build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single build material supply device is used, then device complexity is reduced, but production continuity is interrupted when storage units become empty
Solution Approach 1:
The build material supply system is segmented into multiple independent supply devices (first build material supply device and second build material supply device), each with its own storage unit. This segmentation allows one supply device to be refilled while the other continues supplying material, ensuring production continuity without requiring a completely new system design.
Solution Approach 2:
The system performs preliminary action by having the second supply device prepare and position build material before the first supply device runs out. The control unit coordinates the exchange timing, ensuring the second supply device is ready to take over immediately when the first storage unit becomes empty, thus preventing production interruptions.
2Quantity of substance
If build material storage units are frequently exchanged, then material replenishment is achieved, but additive build process interruptions occur
Solution Approach 1:
The system ensures continuity of useful action by coordinating two supply devices that can operate in sequence. When the first storage unit is depleted, the control unit triggers the second supply device to continue supplying build material without interrupting the additive build process. This overlapping operation eliminates downtime while maintaining continuous material supply.
Solution Approach 2:
The control unit acts as an intermediary that manages the transition between supply devices. It monitors the status of both storage units and coordinates the exchange timing, ensuring smooth handover from the first to the second supply device without disrupting the ongoing build process or requiring manual intervention.
3Productivity
If a dual supply device system is implemented, then production interruptions are avoided, but device complexity increases
Solution Approach 1:
Both the first and second supply devices use identical modular components (storage units, application devices, exchange mechanisms), allowing the same design to serve multiple functions. This universality reduces the actual complexity increase, as the system only doubles the number of identical modules rather than requiring entirely different components for each supply device.
Solution Approach 2:
The system implements self-service through automated control unit coordination. The control unit automatically monitors storage unit status, triggers device exchanges, and manages the transition between supply devices without requiring manual intervention. This automation offsets the increased complexity by eliminating the need for operator involvement in the supply device management.
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 ensures continuous operation of additive manufacturing processes by maintaining a steady supply of build material, reducing downtime, and enhancing overall efficiency.
Implementation Method 1
selective irradiation and consolidation of build material layers by means of at least one energy beam
Implementation Method 2
selective irradiation and consolidation of build material layers by means of at least one energy beam
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Apparatus (1) for additively manufacturing a three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of build material layers (34) by means of at least one energy beam (5) in a build area of the apparatus (1) comprising: - a first build material supply device (8) configured to supply an amount of build material (4) which is to be applied in the build area (BA) of the apparatus (1) by means of a first build material application device (9); - the first build material application device (9) configured to apply an amount of build material (4) in the build area (BA) of the apparatus (1); - a second build material supply device (10) configured to supply an amount of build material (4) which is to be applied in a supply area (SA1) of the first build material supply device (8) by means of a second build material application device (11); - the second build material application device (11) configured to apply an amount of build material (4) in the supply area (SA1) of the first build material supply device (8).