Fluidized Powder Mixing for Homogeneous Additive Manufacturing Feedstock
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in achieving a homogeneous mixture of used and new powder components, which is necessary for producing three-dimensional objects with consistent properties, while also seeking to increase efficiency and reduce waste.
Innovation Solution
A mixing device comprising a first container with a dispensing opening and a second container partially open at the top, combined with fluidization zones and a powder line, allows for a closed-loop mixing process that ensures thorough and reproducible mixing of multiple powder components, including waste and new powders, by introducing gas to facilitate fluidization and using closure devices to control the flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If used powder is mixed with new powder to increase manufacturing efficiency, then productivity and cost-efficiency are improved, but the homogeneity of the powder mixture deteriorates
Solution Approach 1:
The patent employs a fluidization bed system where gas is introduced through a distributor plate to fluidize the powder mixture. This pneumatic approach enables thorough mixing of used and new powder components by creating a fluid-like state that promotes uniform distribution, thereby maintaining homogeneity while enabling efficient mixing of recycled materials.
Solution Approach 2:
The patent controls mixing parameters including gas flow rate, fluidization velocity, and mixing time to optimize the homogeneity of the powder mixture. By adjusting these parameters, the system achieves consistent mixing quality when combining used and new powder, resolving the contradiction between productivity improvement and composition stability.
2Manufacturing precision
If multiple powder components are mixed to meet specific chemical and physical requirements, then the quality of the three-dimensional object is improved, but the complexity of the mixing process increases
Solution Approach 1:
The patent divides the mixing system into distinct functional zones including a fluidization bed, a mixing chamber with multiple powder inlets, and a discharge system. This segmentation allows different powder components to be introduced and mixed in a controlled manner, ensuring quality consistency while managing process complexity through modular design.
Solution Approach 2:
The fluidization bed system serves multiple functions: it fluidizes powder for mixing, enables blending of multiple components, controls particle suspension, and facilitates uniform distribution. This multi-functionality allows the system to handle various powder combinations for different quality requirements without requiring entirely separate mixing systems for each application.
3Stability of the object's composition
If a closed-loop mixing system is implemented to ensure thorough mixing, then the homogeneity of the powder mixture is improved, but the device complexity increases
Solution Approach 1:
The patent integrates the fluidization bed, mixing chamber, and powder circulation system into a unified closed-loop configuration. This merging of functions into a single integrated system achieves thorough mixing and high homogeneity while avoiding the need for multiple separate mixing devices, thereby limiting the increase in overall device complexity.
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 a highly homogeneous powder mixture, simplifies the mixing process, and enables efficient, automated operation, reducing material waste and enhancing the consistency of three-dimensional object production.
Implementation Method 1
The mixing device comprises a first container for receiving the first and/or the second powder component, wherein a dispensing opening for dispensing the first and/or second powder component is provided at a lower boundary of the first container, and a second container for receiving the first and/or the second powder component, wherein the second container is at least partially open towards its upper side.
Data Source
Figure 1
Figure 2~3
Figure 4a~4c
AI summary
A mixing device (18) is used to produce a powder mixture from a first powder component and at least one second powder component for an additive manufacturing device (1). The mixing device (18) comprises a first container (30) for receiving the first and/or the second powder component, wherein a dispensing opening (34) for dispensing the first and/or second powder component is provided at a lower boundary of the first container (30), and a second container (40) for receiving the first and/or the second powder component, wherein the second container (40) is open at least partially towards its upper side. The first container (30) and the second container (40) each have at least one fluidization zone (37 and 47) for introducing a gas into the first container (30) and the second container (40).The mixing device (18) further comprises a powder line (50) which connects to the dispensing opening (34) of the first container (30) and is led into the second container (40).