Intermediate Substrate Powder Transfer for Uniform Layer Deposition
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Solution Overview
Problem
Current material dispensers in powder printing and 3D printing systems face challenges in achieving precise control, uniformity, and high-speed deposition of patterned powder, often requiring additional smoothing and conditioning due to non-uniform powder piles and large particle sizes, which limit feature sizes and printing resolution.
Innovation Solution
A powder transfer system using an intermediate substrate with a directed energy device to disrupt the adhesion of dry powder on a moving surface, allowing precise control and uniform transfer to a target substrate without altering the powder's microstructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a hopper or feeder is used to dispense dry powder onto a substrate, then material deposition is achieved, but the powder forms a nonuniform pile requiring additional smoothing and conditioning
Solution Approach 1:
The patent introduces an intermediate substrate as a mediator between the powder source and the target substrate. The intermediate substrate receives powder, allows it to be smoothed and conditioned, then transfers the uniform powder to the target substrate. This intermediary step enables both high-speed deposition and uniform surface quality without requiring the target substrate to undergo additional processing.
2Manufacturing precision
If hopper/feeder surface geometries, surface coating, agitation, and dispensing mechanism are adjusted to obtain consistent powder mass flow rate, then deposition uniformity improves, but the process remains mechanically agitated resulting in non-uniform powder deposition at high speeds
Solution Approach 1:
The patent replaces the mechanically agitated dispensing system with a gravity-based flow system. Powder flows down the intermediate substrate under gravity without mechanical agitation, allowing consistent mass flow rates even at high deposition speeds. This eliminates the vibration and turbulence caused by mechanical agitation while maintaining uniform powder delivery.
3Productivity
If a sprayer or nozzle is used to deposit powder particles in powder bed systems, then powder can be deposited, but larger particle sizes result in thick layers and rough surfaces limiting feature sizes and printing resolution
Solution Approach 1:
The patent transitions from direct nozzle-to-substrate deposition to an intermediate substrate approach where powder is first deposited onto a moving intermediate surface, then transferred to the target substrate. This dimensional change in the deposition process allows for better powder flow control and surface smoothing before final transfer, resulting in thinner, more uniform layers with improved resolution and reduced surface roughness.
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
Facilitates high-speed, precise, and uniform deposition of patterned powder with controlled feature sizes and shapes, improving deposition speed and quality while maintaining powder properties.
Implementation Method 1
a directed energy device, the directed energy device configured to apply energy to the intermediate substrate to disrupt the adhesion of an adhered layer of the dry powder
Data Source
AI summary
Systems, methods, and other embodiments associated with material deposition. In one embodiment, an apparatus includes an intermediate substrate configured to receive a dry powder, wherein an exterior surface of the intermediate substrate is configured to move and enclose a volume, the intermediate substrate positioned above a target substrate. The example apparatus may also include a powder distribution device configured to distribute the dry powder on the exterior surface of the intermediate substrate, then direct energy from a directed energy device to the intermediate substrate to disrupt an adhesion of an adhered layer of the dry powder along a moving portion of the exterior surface of the intermediate substrate positioned vertically above the target substrate to facilitate transfer of a volume of the dry powder from the intermediate substrate to the target substrate thereby forming a powder layer on the target substrate.