Gas Stream Element for Additive Manufacturing Flue Gas Removal
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in efficiently removing flue gases and dust particles, particularly when producing large products with hollow structures, leading to contamination and quality deviations in the final product.
Innovation Solution
A device and method utilizing a gas stream element with nozzles positioned above and within the building tube to create a controlled gas flow that discharges flue gases and dust particles, ensuring they are removed from the manufacturing area, allowing for improved product quality and reduced powder waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a large powder bed is used to manufacture large products with hollow structures, then the product size and complexity are improved, but the amount of powder waste increases and removal of flue gases becomes less efficient
Solution Approach 1:
The building chamber is segmented into multiple zones using partitions, allowing the powder bed to be divided into separate manufacturing areas. This enables efficient gas removal in each zone while maintaining the capability to manufacture large products with hollow structures, reducing overall powder waste through targeted powder application.
Solution Approach 2:
Hollow structures are manufactured by nesting supports and partitions within the building chamber, creating internal cavities that follow the product geometry. This nesting approach minimizes the volume of powder required while maintaining structural integrity, directly reducing powder waste for large hollow products.
2Device complexity
If a traditional gas stream approach is used to remove flue gases, then the system simplicity is maintained, but the removal efficiency of flue gases and dust particles is insufficient
Solution Approach 1:
The gas removal system is segmented into multiple extraction points positioned at different locations within the building chamber. This segmentation allows targeted removal of flue gases from specific zones, significantly improving overall removal efficiency while maintaining reasonable system complexity through modular design.
Solution Approach 2:
A gas permeable partition is introduced as an intermediary element that allows flue gases to pass through while maintaining physical separation between zones. This mediator enables efficient gas removal without requiring complex piping throughout the entire chamber, balancing simplicity and effectiveness.
3Loss of substance
If the powder bed size is reduced to minimize powder waste, then powder efficiency is improved, but the ability to manufacture large products is compromised
Solution Approach 1:
Powder is applied selectively only in the regions where product material is required, rather than covering the entire building chamber floor. This local quality approach ensures powder efficiency by minimizing waste while maintaining the capability to manufacture large products through precise spatial control of powder deposition.
Solution Approach 2:
The powder bed is extended vertically with multiple layers rather than expanding horizontally. This dimensional change allows manufacturing of large products by building upward in layers, maintaining powder efficiency while achieving the required product volume and complexity.
4Device complexity
If flue gases are not effectively removed, then the system simplicity is maintained, but product quality deteriorates due to contamination
Solution Approach 1:
Flue gases and dust particles are extracted at their source through strategically positioned extraction points near the laser processing zone. This direct extraction approach effectively removes contaminants before they can cause product contamination, maintaining high manufacturing precision with a relatively simple gas removal system.
Solution Approach 2:
A gas permeable partition serves as an intermediary that facilitates the removal of flue gases while maintaining a simple system architecture. The partition allows controlled gas flow without requiring complex mechanical structures, effectively protecting product quality through passive gas management.
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 flue gases and dust particles, enhancing the quality of the manufactured product by preventing contamination and allowing for more efficient use of powder, with improved temperature control and reduced powder bed size requirements.
Implementation Method 1
A gas stream is generated above the building surface... wherein flue gases and/or dust particles, which are formed when the beam of rays strikes the powder layer, are discharged by this gas stream
Implementation Method 2
the powder is locally heated in the various powder layers in order to melt it, at least in part, and then solidify it to form successive layers of the product
Implementation Method 3
the powder is locally heated in the various powder layers in order to melt it, at least in part
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
Device and method for the layered manufacture of a three-dimensional product (1) with a recess (3), in which successive powder layers are applied to a building surface (15) above a building platform (4), wherein this building platform (4) extends in a space between a tube wall (6) of a building tube (5) and an insert provided therein (9), wherein a beam of rays (18) is made to impinge on each powder layer and this beam (18) is moved across the powder layer to form successive layers of said product (1) above the building platform (4), so that the insert (9) extends in said recess (3). According to the invention, a gas stream (24) is generated above the building surface (15), extending above said space, wherein it is made sure that this gas stream (24) crosses said beam of rays (18) wherein flue gases formed while the beam of rays (18) strikes said powder layer, are discharged through this gas stream (24).