Electrostatic Soot Capturing Plate for 3D Printer Build Chamber
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Solution Overview
Problem
In three-dimensional (3-D) printing systems, particularly powder-bed fusion (PBF) printers, the deposition of byproducts such as soot and smoke on beam windows and other components leads to performance degradation, contamination of the powder, and defects in the printed parts, necessitating time-consuming and labor-intensive cleaning processes.
Innovation Solution
The implementation of electrostatically charged plates within the build chamber to attract and repel byproducts, preventing them from contacting beam windows and contaminating the powder, by applying controlled voltages to the plates to manage the movement of contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas flow is used to remove byproducts from the build chamber, then some byproducts are removed, but not all byproducts are removed and build piece defects still occur
Solution Approach 1:
The patent introduces an electrostatic precipitator as an intermediary device between the build chamber and the beam window. This precipitator uses electrostatic fields to capture and remove byproducts from the gas flow before they can deposit on the beam window or build piece, thereby improving both byproduct removal efficiency and build piece quality without compromising the gas flow system.
2Reliability
If beam windows are cleaned frequently to prevent performance degradation, then beam window performance is maintained, but production time is lost and labor costs increase
Solution Approach 1:
The patent implements an electrostatic precipitator system that continuously captures and removes byproducts from the build chamber atmosphere before they can deposit on the beam window. This preliminary action prevents byproduct accumulation on the beam window, maintaining its optical performance over extended periods and eliminating the need for frequent cleaning interruptions.
3Productivity
If byproducts are allowed to deposit on beam windows, then the system operates continuously without cleaning interruptions, but beam window performance degrades and fusion process performance deteriorates
Solution Approach 1:
The electrostatic precipitator serves as an intermediary capture system that removes byproducts from the gas flow path before they reach the beam window. This allows the system to operate continuously without cleaning interruptions while maintaining beam window performance and fusion process quality, as the precipitator intercepts and collects soot and particulates in the build chamber atmosphere.
4Productivity
If byproducts contact the powder or build piece, then the printing process continues uninterrupted, but powder contamination occurs and build piece defects are created
Solution Approach 1:
The electrostatic precipitator acts as an intermediary filtration system that captures byproducts from the build chamber atmosphere before they can contact the powder or build piece. The charged plates in the precipitator attract and collect soot and particulates, preventing their deposition on the build piece and eliminating defects while allowing continuous printing operation.
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 solution enhances the operational performance and efficiency of PBF systems, increases part production yield, prevents powder contamination, and reduces defects in printed pieces by effectively removing byproducts from the build chamber.
Implementation Method 1
an electrostatically charged plate is configured to attract or repel contaminants in the build chamber
Data Source
AI summary
An apparatus and a method for attracting and/or repelling byproducts in a build chamber of a powder-bed fusion system by one or more electrostatically charged plates. The method and apparatus may deliver material to the build chamber of the powder-bed fusion system by a material depositor. An energy beam source may generate an energy beam and apply the energy beam to the material such that the energy beam generates byproducts in the build chamber when applied to the material. One or more electrostatically charged plates are associated with one or more walls of the build chamber to attract and/or repel at least a portion of the byproducts in the build chamber such that the byproducts attached to the surface of the electrostatically charged plates and/or exit the build chamber without damaging a build piece or components of the powder-bed fusion system.