Additive Manufacturing Food Component Surface Quality
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Solution Overview
Problem
Existing additive manufacturing techniques struggle to achieve high surface quality, particularly in the food sector, where a surface roughness of RA ≤ 0.8 µm is required for hygienic bottling. This is challenging due to the formation of pores, binding errors, and uneven surfaces in complex geometries.
Innovation Solution
The proposed solution involves using a jet melting system in an additive manufacturing device to produce components with improved surface quality. This is achieved by generating several contour lines in the contour area and/or multiple exposures, which reduces porosity and surface roughness, and allows for the creation of thicker surface areas. Additionally, the use of a fine powder material with a particle size of up to 20 µm and a thin layer thickness enhances surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing is used, then complex geometries can be produced, but surface quality deteriorates with pores and roughness exceeding hygienic requirements
Solution Approach 1:
The patent applies preliminary action by performing multiple exposures and generating multiple contour lines during the additive manufacturing process itself, before the component is completed. This preliminary surface quality improvement prevents the need for extensive post-processing and ensures hygienic surface standards are met during production.
Solution Approach 2:
The patent employs parameter changes by adjusting beam melting parameters specifically for contour areas versus hatch areas, and by controlling layer thickness and powder particle size. These parameter optimizations enable simultaneous achievement of complex geometries and high surface quality within the same manufacturing process.
2Manufacturing precision
If multiple contour lines and multiple exposures are applied, then surface quality improves with reduced porosity, but manufacturing time increases
Solution Approach 1:
The patent applies local quality by differentiating between contour areas and hatch areas, applying multiple contour lines and multiple exposures selectively only where needed for surface quality (in contour areas), while maintaining faster single-pass processing in hatch areas. This localized application minimizes overall manufacturing time while ensuring surface quality where critical.
3Manufacturing precision
If fine powder material with small particle size is used, then surface quality improves, but material handling and processing complexity increase
Solution Approach 1:
The patent applies parameter changes by optimizing the powder particle size distribution and layer thickness parameters to work together, where the fine powder (≤20 µm) combined with controlled layer thickness achieves high surface quality while maintaining manageable material flow and processing characteristics through parameter coordination.
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 approach significantly improves the surface quality of additive components, achieving a roughness of RA ≤ 0.8 µm, which meets hygienic requirements. The reduced porosity and improved AS-Built surface quality also minimize the risk of microbial contamination and enhance cleanability.
Implementation Method 1
exposing the processing layer by local melting of the powder material
Implementation Method 2
a beam melting system for exposing the processing layer by local melting of the powder material
Implementation Method 3
The beam melting system scans and exposes the processing layer
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
Method and system for the additive manufacturing of a component (116), in particular a component (116) for use with food, by means of an additive manufacturing device (110) comprising a manufacturing section (130) and a jet melting system (140), wherein the method comprises: producing a processing layer (114) from a powder material (112), which is preferably a metallic powder, in the manufacturing section (130) of the additive manufacturing device (110); Exposure of the processing layer (114) by means of the jet melting system (140), whereby the powder material (112) in the processing layer (114) is locally melted, wherein the jet melting system (140) traces and exposes the processing layer (114) in such a way that, by applying hatch process parameters, at least one hatch area (117) and, by applying contour process parameters, at least one contour area (118) of the additively manufactured component (116) are formed;wherein in at least one contour area (118) several adjacent contour lines (118a) are generated and/or the at least one contour area (118) is exposed at least partially multiple times.;