Lid Management System for Additive Manufacturing Build Boxes

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Solution Overview

Problem

Additive manufacturing apparatuses face challenges in maintaining inert gas environments and reducing operator exposure to reactive and combustible powders, which increases costs and time, especially when scaling for commercial production.

Innovation Solution

The implementation of a lid management system with a movable arm and machine lid that sealingly engages the process chamber floor, combined with a build box management system for automated handling of removable build boxes, allows for hands-free operation and preservation of gas environments within the process chamber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If operator manually handles build boxes and manages gas environments, then operator contact with harmful powders is possible, but time and cost increase

Engineering Contradiction:

Improveoperator contact with powdersVSAvoidtime for gas environment management

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system enables automated self-service operation where the lid management system automatically seals and unseals the process chamber, and the build box management system automatically handles build boxes. This eliminates the need for operator intervention in gas environment management and powder handling, thereby reducing both time and cost while maintaining safety.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations by operators are replaced with an automated control system that coordinates the lid management system and build box management system. The control system automates the sequencing of lid sealing, build box insertion, and gas environment maintenance, replacing human labor with automated mechanical and control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If inert gas environment is maintained continuously, then powder reactivity is controlled, but gas consumption and cost increase

Engineering Contradiction:

Improveinert atmosphere maintenanceVSAvoidinert gas consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The process chamber is segmented into a sealed environment where inert gas is maintained only when needed. The lid management system seals the chamber opening when the build box is in place, creating a localized inert atmosphere only during the additive manufacturing process. This prevents continuous gas consumption while maintaining reliable inert conditions during critical operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lid management system seals the process chamber opening in advance before the additive manufacturing process begins, and maintains the seal throughout the build process. This preliminary sealing action ensures the inert gas environment is established and maintained only when required, preventing unnecessary gas consumption while ensuring reliability during the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If build boxes are manually handled, then operator control is maintained, but throughput and productivity decrease

Engineering Contradiction:

Improvethroughput of additive manufacturingVSAvoidautomated handling of build boxes

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The build box management system enables automated self-service handling of build boxes. The system automatically guides build boxes to the process chamber, coordinates their insertion and removal, and manages their positioning. This automated self-service operation increases throughput by eliminating manual handling bottlenecks while maintaining proper control through the control system.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The build box management system performs multiple functions including transport, positioning, sealing coordination, and chamber access management. This multi-functional automated system handles all aspects of build box management, increasing productivity by consolidating multiple operations into a single automated workflow that maintains control while eliminating manual intervention.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If process chamber opening is sealed, then gas environment is preserved, but access for building parts is blocked

Engineering Contradiction:

Improvegas environment preservationVSAvoidaccess to build platform

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The lid management system provides dynamic control of the process chamber opening. The lid can be sealed when the build box is in place to preserve the gas environment, and unsealed when build boxes need to be inserted or removed. This dynamic sealing operation maintains reliable gas environment preservation while enabling access operations at appropriate times through automated control.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20230390825A1Additive manufacturing apparatuses with removable build boxes and lid management systems

Publication Date: 2023.12.07 GENERAL ELECTRIC CO

AI summary

An apparatus for forming a three-dimensional article having successive layers of a powder material, which layers correspond to successive cross-sections of the three-dimensional article includes a process chamber that includes a process chamber floor having an opening therethrough, the opening defining a part processing area and a lid management system. The lid management system includes an actuator including a movable arm that moves between retracted and extended positions and a machine lid connected to the movable arm. The machine lid is sized and configured to sealingly engage a perimeter of the opening of the process chamber floor with the movable arm in the extended position.