Fluidized Powder Application Device for 3D Printing Warpage Reduction
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional objects using powder sintering face issues with powder agglutination due to electrostatic forces and environmental conditions, leading to incomplete stirring and potential warpage during the layer application process.
Innovation Solution
A device and method that utilize a fluidization system with a controlled gas flow and pre-heating of the powder within the application device to ensure homogeneous powder application, preventing agglutination and maintaining a consistent temperature for optimal sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder is fluidized in the supply container by blowing air from below, then agglutination in the supply container is prevented, but agglutination after leaving the supply container is still possible
Solution Approach 1:
The patent applies preliminary action by fluidizing the powder in the supply container before it is transferred to the application device. This pre-fluidization ensures the powder is in a flowable state before leaving the supply container, preventing agglutination during transfer and application. The gas flow is activated in advance to maintain powder流动性 throughout the process.
Solution Approach 2:
The patent uses gas as an intermediary medium to fluidize the powder. The gas flow acts as a mediator between the powder particles, preventing them from adhering to each other through electrostatic forces. This intermediary gas phase enables smooth powder flow from the supply container through the application device without direct particle-to-particle contact that would cause agglutination.
2Stability of the object's composition
If air is blown from below into the building space through a diffuser plate to stir up the powder, then powder stirring is achieved, but the part to be manufactured shadows the powder and incomplete stirring occurs
Solution Approach 1:
The patent inverts the conventional approach by applying powder from above rather than blowing air from below. The application device moves across the building space depositing powder layers from the top, eliminating the shadowing problem that occurs when air is blown from below. This inversion ensures complete and uniform powder application without areas of incomplete coverage.
Solution Approach 2:
The patent uses pneumatic principles to fluidize and transport powder through the application device. Gas flow is used to maintain powder流动性 in the supply container and to facilitate smooth discharge and deposition of powder onto the building space. This pneumatic system ensures uniform powder distribution without the shadowing issues of bottom-blown air systems.
3Reliability
If the powder bed is fluidized by stirring up the powder with air flow, then agglutination is prevented, but the supplied air causes cooling of solidified areas leading to stress and warpage
Solution Approach 1:
The patent segments the fluidization function into two separate locations: the supply container and the application device. Powder is fluidized in the supply container to ensure flowability, then deposited onto the building space. The application device may also fluidize powder locally for uniform application. This segmentation prevents cold air from reaching the building space and cooling solidified parts, while still maintaining powder流动性 where needed.
Solution Approach 2:
The patent applies fluidization locally only where powder handling is required (in the supply container and application device) rather than throughout the entire building space. This localized approach maintains powder流动性 for reliable application while preventing unnecessary cooling of the building space and solidified parts. The gas flow is confined to areas where it serves a functional purpose.
4Manufacturing precision
If powder is applied layer-wise by melting with a laser beam, then three-dimensional objects are manufactured, but agglutination occurs due to electrostatic forces and environmental conditions
Solution Approach 1:
The patent applies preliminary action by fluidizing the powder in the supply container before application. This pre-fluidization ensures the powder is in an optimal flowable state, preventing agglutination before the powder even reaches the application area. The powder is prepared in advance to maintain consistency throughout the layering process, ensuring reliable and uniform application for precise manufacturing.
Solution Approach 2:
The patent uses gas as an intermediary to prevent direct contact between powder particles that would cause agglutination. The gas flow mediates between particles, maintaining separation and流动性. This intermediary gas phase ensures consistent powder application to the laser beam, improving manufacturing precision by eliminating agglutination-related defects.
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 achieves more uniform and complete powder application, reducing the risk of agglutination and warpage, while allowing for efficient and controlled powder flow, which enhances the quality of the three-dimensional objects produced.
Implementation Method 1
a fluidization device (43) integrated into the application device (40) for fluidizing the powder
Implementation Method 2
a heating device (46) integrated into the application device (40) for pre-heating the powder
Data Source
AI summary
A device and a method for manufacturing a three-dimensional object (3) by solidifying layers (25) of a material in powder form at those positions corresponding to the respective cross-section of the object (3) are provided. The device comprises an application device (40) for applying layers of the material in powder form (47) in the building area (5), which can be moved over the building area (5). The application device (40) is formed to have a first longitudinal wall (41a) and a second longitudinal wall (41b) that are connected to one another via two side walls. The application device (40) is provided with a fluidization device for homogenizing the material in powder form (47). This fluidization device comprises at least one hollow body having escape openings in its walls, through which escape opening a gas can flow from the hollow body into the material in powder form (47).