Foldable Powder Receiving Means for Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing machines using thermal energy to melt and fuse metal powders face challenges in efficiently removing unfused powders from the fusion chamber without spilling, which restricts cooling time and manufacturing cycle duration.

Innovation Solution

The machine incorporates a foldable powder receiving means with hinged partitions that can be manually unfolded to contain and guide unfused powders towards spillways, allowing for quick and safe discharge and reduced cooling time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If the table supporting the fusion tray is raised to remove unfused powder, then powder discharge is enabled, but powder spills into the machine enclosure

Engineering Contradiction:

Improveunfused powder dischargeVSAvoidpowder spillage into machine

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The receiving means is divided into four separate partitions (right-hand, left-hand, front, and rear) that can be independently positioned and configured. This segmentation allows each partition to work together to contain and direct powder flow along the periphery toward designated spillways, preventing uncontrolled spillage into the machine enclosure while enabling effective powder discharge.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The receiving means acts as an intermediary structure between the fusion chamber and the machine enclosure. It intercepts unfused powder that would otherwise spill directly into the machine, channels it along controlled paths along its periphery, and directs it through designated spillways to designated collection areas, thus mediating the powder discharge process to prevent harmful spillage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a frame is placed in the chamber to prevent powder spillage, then powder containment is improved, but the device size increases and hinders manufacturing

Engineering Contradiction:

Improvepowder containmentVSAvoidframe structure size

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The receiving means incorporates hinged connections at its corners, allowing it to dynamically adjust its configuration. The partitions can be folded or positioned to create containment walls when needed, and can be adjusted or collapsed when not required, transforming from a static obstructive structure to a dynamic adaptive structure that provides containment only when necessary for powder discharge.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The receiving means utilizes the vertical dimension and peripheral space along the fusion chamber walls rather than occupying central manufacturing space. By positioning partitions along the periphery and using vertical height to contain powder, it creates containment in three-dimensional space without interfering with the two-dimensional manufacturing area, thus preventing powder spillage without hindering piece manufacturing.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Object-affected harmful factors

If the receiving means is fixed and large, then powder containment is effective, but cooling time increases due to restricted chamber access

Engineering Contradiction:

Improvepowder containmentVSAvoidcooling time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The hinged connections enable the receiving means to be dynamically reconfigured during the cooling phase. After powder discharge is complete, the partitions can be folded inward or collapsed, reducing the occupied volume and allowing faster heat dissipation from the manufactured piece. This dynamic adjustment reduces thermal mass and improves air circulation around the piece, thereby reducing cooling time while maintaining containment effectiveness during the discharge phase.

Inventive Principle:

Principle #15Dynamics

4Temperature

If powder is removed to accelerate cooling, then cooling speed increases, but powder spills into the machine enclosure

Engineering Contradiction:

Improvecooling speedVSAvoidpowder spillage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The receiving means serves as an intermediary containment structure that allows rapid powder removal to accelerate cooling while preventing spillage. By providing controlled discharge paths along its periphery to designated spillways, it enables the powder to be quickly evacuated from around the manufactured piece (accelerating cooling) while intercepting and redirecting the powder flow away from the machine enclosure (preventing spillage).

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12303977B2Means for receiving powder in an additive manufacturing machine

Publication Date: 2025.05.20 SAFRAN LANDING SYSTEMS

AI summary

An additive manufacturing machine includes a system for receiving powder, including four sides: a right-hand partition and a left-hand partition, a front partition and a rear partition, wherein at least two opposite sides each includes two hinged portions allowing the folding of the sides. The system is foldable and can be easily placed in the melt chamber without interfering with the manufacturing process; it can therefore be placed in the chamber before manufacturing.