Metering Metallic Powder in 3D Printing Using Intermediary Tool
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Solution Overview
Problem
In binder jetting additive manufacturing, there is a challenge in efficiently metering and depositing non-flowable metallic powders onto a powder bed without clogging, as they tend to clump and require precise control of motion and gap sizes to facilitate flow.
Innovation Solution
A method and system that utilize a moveable surface with a controlled gap and motion to meter metallic powders from a hopper, where the gap and motion enable predictable flow onto a powder bed, combined with a leveler and printhead to form uniform layers and apply binder fluid for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a gap is provided between the opening and moveable surface to enable powder flow, then the powder material can flow from the powder supply, but the flow control precision deteriorates due to the gap allowing uncontrolled spillage
Solution Approach 1:
A tool is introduced as an intermediary element between the moveable surface and the powder material. The tool contacts the powder material and forces it off the moveable surface in a controlled manner, preventing uncontrolled spillage while maintaining the gap's flow-enabling function. The tool acts as a mediator that transforms the uncontrolled flow potential into controlled deposition.
Solution Approach 2:
The patent replaces a purely mechanical flow control system with a hybrid system that includes a tool interface. Instead of relying solely on the gap geometry to control flow, the tool provides an additional mechanical interface that actively guides and controls the powder material departure from the moveable surface, enhancing precision.
2Manufacturing precision
If the gap size is reduced to improve flow control, then manufacturing precision improves, but the productivity deteriorates due to increased clogging risk
Solution Approach 1:
The tool serves as a mediator that allows the use of smaller gap sizes without sacrificing productivity. By actively guiding the powder material off the moveable surface, the tool prevents clogging that would otherwise occur with reduced gap sizes, thereby maintaining both precision and deposition rate.
Solution Approach 2:
The system employs dynamic control where the tool interacts with the powder material in real-time during the deposition process. This dynamic interaction allows the gap size to be optimized for precision while the tool's motion and positioning compensate for any flow restrictions, maintaining productivity.
3Productivity
If the moveable surface motion speed is increased to improve productivity, then the deposition rate increases, but the manufacturing precision deteriorates due to uneven powder distribution
Solution Approach 1:
The tool acts as a mediator between the moveable surface and the powder bed, ensuring uniform powder distribution even at higher deposition rates. The tool's controlled interaction with the powder material compensates for the reduced residence time caused by faster motion, maintaining layer uniformity while increasing productivity.
Solution Approach 2:
The system dynamically adjusts operational parameters including the tool's position, contact force, and motion characteristics in coordination with the moveable surface speed. This parameter optimization allows high-speed deposition while maintaining precision through adaptive control of the tool-powder interaction.
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 reliable and uniform deposition of metallic powders, preventing clogging and ensuring consistent layer formation for 3D object creation, with the system effectively bonding layers to form a finished 3D part.
Implementation Method 1
metering a powder material at an opening of a powder supply storing the powder material to produce a flow of the powder material away from the powder supply and onto a moveable surface located beneath the opening
Implementation Method 2
leveling the metered amount across the top surface of the powder bed to form a layer of the powder material
Implementation Method 3
applying a binder fluid to at least one region of the layer, the binder fluid causing powder material of the layer to become bonded at the at least one region
Data Source
AI summary
A metering apparatus and corresponding method meter a powder material in a three-dimensional (3D) printing system. The metering apparatus comprises a hopper with walls configured to contain a powder material, a metering roller, and a tool. The metering roller is located beneath an opening of the hopper. The metering roller and a given wall of the walls of the hopper are spaced apart by a gap therebetween at the opening; the gap in combination with rotation of the metering roller causes the powder material to flow from under the given wall of the hopper at a substantially predictable rate. The tool is positioned at the given wall where the flow emerges and is configured to force the powder material off of the metering roller to supply the 3D printing system with the powder material for printing a 3D object.