Metal 3D Printer Obstacle Removal via Blade Collision
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Solution Overview
Problem
Existing 3-D printing technologies face inefficiencies in removing obstacles and surplus thickness from sintered layers, leading to prolonged molding times due to the difficulty in accurately targeting and removing minute protrusions and the need for frequent removal of surplus thickness, even when obstacles are not present.
Innovation Solution
A metal 3-D printer equipped with a numerical control apparatus that includes a collision detector and a machining apparatus with a cutting tool, which lowers and moves the cutting tool to remove obstacles only when collisions occur, ensuring precise removal and reducing the need for frequent surplus thickness removal, thereby shortening the molding time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cutting tool is used to remove obstacles from the sintered layer, then obstacles can be removed, but the molding time becomes unnecessarily long due to piecewise removal of minute protrusions
Solution Approach 1:
The system performs preliminary detection of obstacles using the blade collision detection mechanism before resuming powder layer formation. By detecting obstacles early and addressing them promptly, the system avoids the time-consuming piecewise removal process and prevents interruptions to the overall molding workflow.
2Reliability
If surplus thickness is removed from the sintered layer each time a layer is formed, then obstacles are removed, but the molding time becomes unnecessarily long due to repeated removal operations
Solution Approach 1:
The blade serves dual functions: it both forms the powder layer and detects obstacles through collision detection. This self-service mechanism eliminates the need for separate, time-consuming surface inspection and removal operations, as the blade naturally identifies obstacles during the powder layer formation process itself.
3Manufacturing precision
If the blade planarizes the powder layer, then a smooth surface is formed, but the blade collides with protrusions greater than 50 μm height, stopping the molding process
Solution Approach 1:
The system implements feedback through the collision detector that monitors blade interactions with the powder layer and sintered surface. When the blade collides with a protrusion, the collision detector generates a signal that triggers obstacle removal operations, allowing the system to automatically correct issues and resume molding without manual intervention or complete process stoppage.
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 solution ensures efficient removal of obstacles and reduces the time required for obstacle removal, ensuring accurate and timely completion of the 3-D printing process without the need for operator input of precise lowering distances, even when powder layer thicknesses change.
Implementation Method 1
a laser beam irradiating device (5) for irradiating a laser beam on the powder layer to form a sintered layer
Implementation Method 2
a blade for planarizing metal powder and moving the blade horizontally to form a powder layer on the substrate or a sintered layer
Data Source
AI summary
A metal 3-D printer includes a powder layer formation device having a blade for planarizing metal powder, a table driving device lowering a table by a predetermined lowering distance in anticipation of a formation of a powder layer, a laser irradiating device irradiating a laser beam at the powder layer to form a sintered layer having a predetermined upper surface region, a numerical control apparatus controlling the powder layer formation device, the table driving device, the laser irradiating device and a machining apparatus. When the blade collides with an obstacle formed on an upper most sintered layer, an end mill is lowered according to a predetermined lowering distance such that a lower end of the end mill is lower than an upper surface of the powder layer, and moves the end mill across a predetermined upper surface region of the uppermost sintered layer to remove the obstacle.