Inflatable Powder Seal Assembly for Stable Low-Volume Powder Beds

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In powder bed additive manufacturing, the manual loading and handling of additive powder are time-consuming and costly, and the process requires large volumes of powder, which can lead to inefficiencies and failures due to powder collapse during printing, especially for components with large dimensions like compressor blades in gas turbine engines.

Innovation Solution

An additive manufacturing machine equipped with a powder seal assembly that includes a powder support plate with an inflatable sealing element, allowing for precise powder deposition and minimizing the amount of additive powder needed by creating a sealed surface above the build platform, enabling efficient repair of components without filling the entire powder bed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the entire powder bed is filled with additive powder to enable printing on large components like compressor blades, then the build platform can support the full component height, but the powder loading process becomes time-consuming and costly, and large volumes of powder are consumed

Engineering Contradiction:

Improvecomponent heightVSAvoidpowder loading time

Core Design Contradiction:

Volume of moving objectVSLoss of time

Solution Approach 1:

The build space is segmented into a used powder region and a reusable powder region by the powder support plate. The plate creates a physical boundary that separates freshly deposited powder from powder that can be collected and reused, enabling efficient powder management for large component builds.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The powder support plate acts as an intermediary structure between the build platform and the powder supply system. It provides a stable surface for powder deposition without requiring the entire build chamber to be filled, thus reducing powder consumption and loading time while supporting tall components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If large volumes of additive powder are used to fill the powder bed for large components, then sufficient support is provided for the build, but powder collapse during printing can occur resulting in process failure

Engineering Contradiction:

Improvepowder volumeVSAvoidprinting reliability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The powder support plate provides localized support exactly where powder is deposited, creating a stable build surface in the critical printing zone. This localized support prevents powder collapse without requiring excessive powder volume throughout the entire build chamber, thereby improving printing reliability.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If manual loading and handling of additive powder is performed for large component builds, then the powder bed can be prepared for printing, but the process becomes time-consuming and costly

Engineering Contradiction:

Improvepowder bed preparationVSAvoidpowder handling time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The powder support plate enables recovery and reuse of powder in the reusable region after printing is complete. Instead of discarding all unused powder, the system allows selective recovery, reducing both material cost and the time required for powder handling in subsequent builds.

Inventive Principle:

Principle #34Discarding and recovering

4Volume of moving object

If the powder bed is filled to accommodate large component dimensions, then the full component can be built, but excessive powder must be added prior to printing and removed after printing

Engineering Contradiction:

Improvecomponent volumeVSAvoidpowder waste

Core Design Contradiction:

Volume of moving objectVSLoss of substance

Solution Approach 1:

The powder support plate segments the powder bed into a consumption zone and a reusable zone. This segmentation ensures that powder used in the reusable zone can be recovered and reused, significantly reducing powder waste while still accommodating large component volumes in the consumption zone.

Inventive Principle:

Principle #1Segmentation

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 reduces the amount of additive powder required, simplifies the powder loading process, and enhances the reliability of the additive manufacturing process by maintaining a stable powder bed, thereby improving efficiency and reducing costs associated with powder usage and handling.

Implementation Method 1

the inflatable sealing element is configured for inflating to contact and seal against the component

Methodology Applied

Scientific EffectInflation: Pressure Increase

Data Source

PatentUS11407035B2Powder seal assembly for decreasing powder usage in a powder bed additive manufacturing process

Publication Date: 2022.08.09 GENERAL ELECTRIC CO

AI summary

An additive manufacturing machine for repairing a component includes a build platform that supports the component and a powder dispensing assembly for selectively depositing additive powder over the build platform. A powder seal assembly includes a powder support plate positioned above the build platform and defining an aperture for receiving the component without contacting the component. An inflatable sealing element is operably coupled to the powder support plate around the aperture and is inflated to contact and seal against the component, thereby forming a support surface above the build platform upon which additive powder may be deposited.