Moving Aperture Shield for LPBF Spatter Control
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Solution Overview
Problem
Spatter generated during laser powder bed fusion (LPBF) leads to oxide formation, non-uniform layer thickness, incomplete melting, and increased surface roughness, resulting in degraded build properties and limited build chamber size due to material defects.
Innovation Solution
A spatter protection system with a sheet having an aperture to redirect spatter away from the build area, supported by a motive system that tracks the energy application spot and includes rollers and actuators to position the aperture over the energy application area, allowing spatter to eject through the aperture and land on the sheet's back side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional spatter protection methods (gas manifold modifications, part placement, scan strategy) are used, then spatter deflection is achieved, but build chamber size is limited and build properties are degraded
Solution Approach 1:
The patent employs a dynamic shield that moves with the laser beam during additive manufacturing. The shield is positioned and oriented in real-time to intercept spatter generated at the laser-powder interaction zone, allowing the build chamber size to be increased without compromising spatter protection effectiveness.
Solution Approach 2:
The patent introduces a physical shield as an intermediary element between the laser-powder interaction zone and the build area. This shield actively intercepts spatter material, preventing it from contaminating the build chamber while allowing the chamber size to be expanded beyond conventional limitations.
2Object-affected harmful factors
If conventional spatter protection methods are used, then spatter deflection is achieved, but build properties are degraded due to oxide formation, non-uniform layer thickness, and surface roughness
Solution Approach 1:
The dynamic shield tracks the laser beam position and adjusts its orientation to optimally intercept spatter. This real-time adaptation ensures that spatter is redirected away from the build area without interfering with the laser-powder interaction, thereby maintaining manufacturing precision and build quality while protecting against contamination.
Solution Approach 2:
The shield acts as an intermediary that captures and redirects spatter material before it can contaminate the build area. By positioning the shield strategically in the spatter trajectory path, the system prevents oxide formation, maintains uniform layer thickness, and reduces surface roughness without affecting the laser processing quality.
3Object-affected harmful factors
If a static shield is used to block spatter, then spatter protection is achieved, but the energy beam cannot pass through effectively and build area is reduced
Solution Approach 1:
The shield is designed to move and adjust its position dynamically during the additive manufacturing process. It positions itself to intercept spatter trajectories while maintaining clear paths for the energy beam to reach the powder bed, thereby protecting against contamination without compromising energy transmission efficiency.
Solution Approach 2:
The shield is positioned strategically in specific zones where spatter trajectories intersect, rather than creating a complete barrier. This localized protection approach allows the energy beam to pass through unobstructed to the build area while still effectively intercepting and redirecting spatter material away from sensitive regions.
Data Source
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AI summary
A spatter protection system (100) for an additive manufacturing machine can include a sheet (101) configured to be disposed over a build area (103) of the additive manufacturing machine. The sheet (101) can include an aperture (105) configured to allow a spatter from the build area (103) to eject through the aperture (105) during energy application and to land on a back side (101a) of the sheet to prevent the spatter from landing on the build area (103). The system can include a motive system (107) supporting the sheet (101) and configured to move the sheet (101) to locate the aperture (105) over an energy application area.