Selective Laser Sintering Chamber with Dynamic Temperature Zones
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Solution Overview
Problem
Current additive manufacturing methods, such as selective laser sintering, are limited by the size of the chamber and the cost of equipment, making it difficult to efficiently produce large parts like aircraft components without the need for extensive and costly setup, and traditional methods are time-consuming and expensive.
Innovation Solution
A method and apparatus that uses layers of precursor material, selectively cured using a curing system, to form objects and frames, allowing for the incremental growth of parts within a chamber without the need for a fixed large chamber, using a movement system to support the frame and temperature control to manage the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to produce large parts, then production time and cost are reduced, but the chamber size must be increased which increases equipment cost
Solution Approach 1:
The patent divides the manufacturing chamber into multiple zones along the build direction, with each zone having its own heating and cooling control. This allows the chamber to be physically compact while effectively processing large parts by sequentially moving the build platform through different temperature zones, thus resolving the contradiction between chamber size and productivity
Solution Approach 2:
The patent implements dynamic temperature control by moving the build platform through heated and cooled zones during the manufacturing process. This dynamic approach allows a standard-sized chamber to accommodate and process large parts that would otherwise require a much larger static chamber, thereby reducing equipment cost while maintaining high productivity
2Productivity
If additive manufacturing is used to produce large parts, then production time is reduced, but equipment cost increases due to larger chamber size
Solution Approach 1:
The heating and cooling systems are segmented into discrete zones that can independently control temperature in different regions of the chamber. This modular approach allows the use of standard-sized equipment with sophisticated control, rather than requiring expensive oversized chambers, thus reducing equipment cost while maintaining fast production
Solution Approach 2:
The patent changes the temperature parameters dynamically during the manufacturing process by moving the build platform through heated and cooled zones. This parameter control approach allows large parts to be manufactured in standard-sized chambers, reducing equipment cost while maintaining high productivity
3Volume of moving object
If traditional manufacturing methods are used, then large parts can be produced, but lead time and equipment cost increase
Solution Approach 1:
The patent uses dynamic temperature zone movement to enable large part production in standard-sized chambers. The build platform moves through heated and cooled zones during manufacturing, allowing large parts to be produced additively with fast lead times, eliminating the need for traditional slow mold-making processes
4Manufacturing precision
If temperature control is applied to maintain desired temperature in different locations, then part quality is maintained, but energy consumption increases
Solution Approach 1:
The temperature control system is segmented into discrete heated and cooled zones that can be independently controlled. Only the specific zones where material is being deposited require active heating, while other zones use passive cooling or insulation, significantly reducing overall energy consumption while maintaining part quality
Solution Approach 2:
The heating and cooling zones move periodically along with the build platform, providing temperature control only when and where needed during the manufacturing process. This periodic action reduces energy consumption compared to maintaining uniform temperature throughout the entire chamber, while still ensuring high manufacturing precision
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
Enables the efficient production of larger parts, like aircraft components, by allowing incremental growth within a standard-sized chamber, reducing production time and costs, and maintaining part quality by controlling temperature and density of the precursor material.
Implementation Method 1
With selective laser sintering, a laser system may direct a laser beam to selectively heat portions of the layer of powder to form a portion of the object
Implementation Method 2
The layers of precursor material may be selectively cured as the layers of precursor material are placed on top of each other to form an object and a frame associated with the object
Implementation Method 3
A desired temperature for the portion of the aircraft part may be maintained in different locations in the chamber as the aircraft part is formed using a plurality of heating and cooling elements
Implementation Method 4
The uncured precursor material may be cooled to change a density of the uncured precursor material such that a flow of gas through the precursor material is reduced
Data Source
AI summary
A method and apparatus for forming objects. Layers of precursor material may be placed on top of each other. The layers of precursor material may be selectively cured as the layers of precursor material are placed on top of each other to form an object and a frame associated with the object.