Laminar Vertical Powder Flow Additive Manufacturing

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Solution Overview

Problem

Existing laser additive manufacturing processes are time-consuming and lack uniformity due to the requirement of spreading a thin layer of powder over a horizontal build plate, necessitating a need for higher throughput and uniformity.

Innovation Solution

A method and apparatus utilizing a vertically oriented build plate with a powder curtain created by a hopper with a linear opening, where a focused energy beam, such as a laser, sinters or melts powder onto the plate, allowing for continuous three-dimensional structure building by adjusting the distance between the powder curtain and the build plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a recoater arm or hopper is used to spread powder over a horizontal build plate, then the powder can be distributed across the build surface, but the process becomes time-consuming and lacks uniformity

Engineering Contradiction:

Improveuniformity of powder layerVSAvoidthroughput of additive manufacturing process

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent inverts the conventional horizontal build plate approach by using a vertical build plate with powder delivered from above. This inversion eliminates the need for recoater arms to spread powder horizontally, allowing gravity-assisted uniform powder delivery and eliminating the time-consuming spreading step while maintaining layer uniformity

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts and eliminates the recoater arm component from the system. By removing the mechanical spreading mechanism entirely and replacing it with a vertical powder delivery system, the process achieves both higher throughput (by eliminating the spreading step) and improved uniformity (through consistent vertical powder flow)

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If a roller or arm is used to spread powder over the build plate, then the powder can be distributed, but the process requires multiple time-consuming steps for each layer

Engineering Contradiction:

Improvesimplicity of powder distribution processVSAvoidtime required per layer deposition

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent enables continuous powder delivery and layer deposition by eliminating the stop-start nature of recoater arm operation. The vertical powder curtain system maintains continuous material flow to the build plate, allowing the laser to continuously process powder without interruption for powder redistribution, thereby reducing time per layer and simplifying the overall operation

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If conventional horizontal powder spreading is used, then existing apparatus can be utilized, but the process lacks high throughput and uniformity

Engineering Contradiction:

Improvethroughput of manufacturing processVSAvoiduniformity of powder layer deposition

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent transitions from horizontal powder spreading (2D surface operation) to vertical powder delivery (3D spatial operation). By delivering powder vertically from above the build plate and using a vertical build plate orientation, the system achieves both high throughput (through continuous vertical deposition) and high uniformity (through consistent gravitational flow and controlled powder curtain)

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 eliminates the need for a roller arm or hopper to coat horizontal layers, enabling a continuous and more efficient additive manufacturing process with improved uniformity and throughput.

Implementation Method 1

scanning a focused energy beam on a region of the vertical curtain to sinter or melt the powder to the vertical oriented build plate

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

scanning a focused energy beam on a region of the vertical curtain to sinter or melt the powder

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

The powder curtain is preferably a laminar flow of powder

Methodology Applied

Scientific EffectLaminar flow: Laminar Flow

Data Source

PatentUS10675683B2Laminar vertical powder flow for additive manufacturing

Publication Date: 2020.06.09 GENERAL ELECTRIC CO

AI summary

A method and apparatus for additive manufacturing is provided whereby a curtain of powder is provided adjacent a vertically oriented build plate, and a laser melts or sinters the powder over a region of the build plate. The curtain of powder is moved relative to the build plate to maintain the same distance between the curtain and the previously deposited layer, and the process repeated to provide a three dimensional structure on the build plate.