Flexible Scraper and Segmented Vacuum Nozzles for Selective Powder Removal
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Solution Overview
Problem
In binder jetting 3D printing, there is a need for efficiently removing unnecessary powder from substrates, particularly from areas between adjacent print layers, without disturbing the powder in regions meant for further processing.
Innovation Solution
An apparatus comprising a blade and vacuum nozzles is used to remove powder from specific areas of a substrate. The blade scrapes powder from designated regions without touching adjacent areas, while the vacuum nozzles, including edge and central nozzles, collect the scraped powder without disturbing the powder on adjacent portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a blade is used to scrape powder from the substrate, then powder removal from designated areas is improved, but powder may be accidentally removed from adjacent portions
Solution Approach 1:
The vacuum system is segmented into multiple independent vacuum nozzles (first vacuum nozzle, second vacuum nozzle, third vacuum nozzle) positioned at different locations. Each nozzle serves a specific region, allowing selective powder removal from designated areas while preserving powder on adjacent portions through localized vacuum action.
Solution Approach 2:
Different regions of the substrate receive different treatments through strategically positioned vacuum nozzles. The first vacuum nozzle targets powder near the first edge, the second vacuum nozzle targets powder near the second edge, and the third vacuum nozzle targets central powder, creating locally optimized powder removal that maintains precision.
2Productivity
If vacuum nozzles are used to collect scraped powder, then powder collection is improved, but powder on adjacent portions may be disturbed
Solution Approach 1:
The vacuum collection system is divided into multiple independent nozzles positioned at specific locations. This segmentation allows each nozzle to collect powder from its designated area without interfering with powder on adjacent portions, maintaining both collection efficiency and powder integrity.
Solution Approach 2:
The vacuum nozzles act as intermediaries between the scraped powder and the collection system. By positioning these intermediaries at specific locations and using controlled vacuum pressure, powder is selectively collected from designated areas while the powder on adjacent portions remains undisturbed.
3Speed
If the blade moves across the substrate to remove powder, then processing speed is improved, but control over which areas are cleaned becomes difficult
Solution Approach 1:
The substrate processing is segmented into distinct zones with vacuum nozzles positioned at specific locations (first edge, second edge, center). This spatial segmentation allows the blade to move across the substrate at high speed while the vacuum nozzles selectively remove powder from designated areas, maintaining both processing speed and area selection precision.
Solution Approach 2:
The vacuum nozzles are pre-positioned at specific locations on the substrate before the blade passes. This preliminary positioning ensures that when the blade moves across the substrate at high speed, powder is already being collected from the correct areas, maintaining precision without sacrificing processing speed.
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
The solution effectively removes powder from specified areas while maintaining powder integrity on adjacent regions, facilitating precise processing in 3D printing and enabling clean separation between print layers.
Implementation Method 1
a pair of edge vacuum nozzles and a central vacuum nozzle, located between the pair of edge vacuum nozzles, wherein each edge vacuum nozzles and the central vacuum nozzle is configured to move with the blade to remove powder from both edges of the first portion and a central region of the first portion
Data Source
AI summary
An improved apparatus and method are provided to remove powder from a web, for example, in a 3D printing apparatus. A flexible blade is provided to contact and move across a first portion of the web located between adjacent portions of the web to scrape powder from the first portion without removing powder deposited on the adjacent portions. A pair of edge vacuum nozzles and a central vacuum nozzle are also provided to move with the flexible blade to remove powder from both edges of the first portion and a central region of the first portion.