Indirect Additive Manufacturing Binder Drop Counting
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Solution Overview
Problem
Indirect additive manufacturing by projection of binding on a powder bed faces challenges in maintaining the geometry of the final part due to dimensional changes during the manufacturing process, which affects the productivity and quality of the parts produced.
Innovation Solution
The implementation of an indirect additive manufacturing installation that includes a support, a powder supply system, a print head for selective binder projection, and a drop counting device to accurately measure and control the binder distribution on each powder bed, allowing for precise geometric control and optimization of the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If binder is projected onto powder bed and then cured and sintered, then productivity is improved compared to LPBF, but dimensional changes occur during manufacturing making geometry control difficult
Solution Approach 1:
The patent implements a feedback mechanism by counting the actual number of binder drops projected onto the powder bed and using this information to adjust subsequent printing parameters. This closed-loop control compensates for dimensional changes during curing and sintering, maintaining geometric accuracy while preserving the high productivity of binder jetting processes.
Solution Approach 2:
The patent changes the parameter of binder drop volume and number based on real-time counting and dimensional change data. By dynamically adjusting these parameters, the system compensates for the dimensional changes that occur during curing and sintering, thereby maintaining geometric precision without sacrificing manufacturing speed.
2Adaptability or versatility
If binder projection is performed to create green part, then part can be manufactured with complex geometry, but dimensional changes during curing and sintering affect final part geometry
Solution Approach 1:
The patent performs preliminary action by counting binder drops during the printing stage and using this data to pre-calculate compensation parameters before curing and sintering. This allows the system to anticipate and compensate for dimensional changes, ensuring accurate final dimensions while maintaining the ability to manufacture complex geometries.
Solution Approach 2:
The system uses feedback from drop counting and dimensional measurement to continuously refine printing parameters for complex geometries. This ensures that even as part complexity increases, the final dimensions remain accurate through iterative compensation based on actual process data.
3Strength
If more binder is projected to ensure sufficient saturation of powder bed, then green part strength is improved, but dimensional changes increase making geometry control more difficult
Solution Approach 1:
The patent dynamically changes the binder drop volume and distribution parameters based on real-time counting and feedback. By optimizing these parameters, the system achieves sufficient green part strength for depowdering while minimizing excessive binder that would cause problematic dimensional changes during subsequent processing.
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 solution enables better control over the additive manufacturing process, reducing dimensional changes and improving the geometric accuracy of the final parts, while also increasing productivity and optimizing the quality of the manufactured parts.
Implementation Method 1
a print head configured to selectively project binder onto each of the successive powder beds
Implementation Method 2
This binder dries at least partially
Implementation Method 3
the binder is crosslinked into a solid polymer to ensure the part, which is then called 'green', has sufficient mechanical strength
Data Source
Figure 1~2
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Figure 5
AI summary
An indirect additive manufacturing installation (10) by spraying binder (16) onto a powder bed (14), comprising a support (12), a powder supply means (32) configured to form successive powder beds (14) on the support (12), a print head (18) configured to selectively spray binder (16) onto each of the successive powder beds (14), and a counting device (40) for the binder droplets (16) sprayed by the print head (18) onto the powder beds (14). An indirect additive manufacturing process by spraying binder onto a powder bed, comprising the formation of successive powder beds (14) on a support, the selective spraying of binder (16) onto each of the powder beds (14), the process further comprising counting the sprayed binder droplets.