Modular Powder Application Device for Additive Manufacturing
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Solution Overview
Problem
Existing systems for producing three-dimensional workpieces by applying electromagnetic radiation or particle radiation to powder layers face challenges in efficiently smoothing and managing raw material powder layers during the additive layer construction process, particularly in laser melting or laser sintering systems.
Innovation Solution
A carrier and powder application device with a modular design featuring multiple powder chambers, each with a powder outlet opening, and a smoothing slide to level and smooth the powder layers, allowing for continuous or discontinuous powder feeding and selective application of different powders, with control mechanisms for precise powder discharge and layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single powder reservoir is used, then the device structure is simple, but it cannot prevent contamination between different powders and requires empty runs when switching materials
Solution Approach 1:
The single powder reservoir is divided into multiple separate powder reservoirs (first powder reservoir, second powder reservoir, etc.), each capable of storing different powder materials. This segmentation allows the system to switch between different powders without empty runs and prevents contamination, while the modular design keeps the overall structure manageable through standardized components like distribution devices and scraper elements.
Solution Approach 2:
The distribution device is designed with universal functionality to work with multiple powder reservoirs and distribute different powders to the same build area. The scraper elements and distribution mechanisms are configured to handle various powder types uniformly, allowing the system to adapt to different material requirements without requiring completely different application mechanisms for each powder type.
2Reliability
If multiple powder reservoirs are used, then contamination is prevented and material switching efficiency improves, but the device structure becomes more complex
Solution Approach 1:
The system divides the powder storage function into multiple independent reservoirs, each dedicated to a specific powder type. This physical separation guarantees that powders cannot contaminate each other, while the modular architecture allows each reservoir to be independently managed, reducing the complexity burden of having multiple reservoirs.
Solution Approach 2:
The distribution device acts as an intermediary between multiple powder reservoirs and the build area. It centralizes the powder delivery function, coordinating the flow from multiple reservoirs through a unified distribution mechanism, which simplifies the overall system architecture compared to having separate delivery systems for each reservoir.
3Productivity
If powder layers are not smoothly leveled, then the application process is faster, but the quality of workpiece production deteriorates
Solution Approach 1:
The scraper elements are positioned to level and smooth the powder layers immediately after powder distribution, before the next processing step. This preliminary action ensures that the powder surface is properly prepared for subsequent operations, maintaining high manufacturing precision without requiring additional processing time later in the cycle.
Solution Approach 2:
The distribution device incorporates integrated scraper elements that automatically level and smooth the powder as it is being deposited. This self-service mechanism performs the smoothing function concurrently with the powder application process, eliminating the need for separate smoothing operations and maintaining productivity while ensuring high surface quality.
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 efficient and precise application of raw material powders, preventing contamination and avoiding 'empty runs' during the production process, thereby improving the quality and efficiency of workpiece production by ensuring smooth, level powder layers and allowing for the use of various powders in a controlled manner.
Implementation Method 1
laser radiation is applied to it in a location-selective manner. The laser radiation penetrating the powder layer causes heating and consequently a fusion or sintering of the raw material powder particles
Implementation Method 2
The laser radiation penetrating the powder layer causes heating and consequently a fusion or sintering of the raw material powder particles
Implementation Method 3
The laser radiation penetrating the powder layer causes heating and consequently a fusion or sintering of the raw material powder particles
Data Source
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AI summary
A powder application device (10; 10') for use in a plant for the production of workpieces by applying layers of powder with electromagnetic radiation or particle radiation comprises a powder supply opening (18a-18d; 18') and a powder chamber (14; 14') for receiving raw material powder to be applied to a carrier (12) of the plant for the production of workpieces by applying layers of powder with electromagnetic radiation or particle radiation. The powder room (14; 14') comprises at least two separate powder chambers (16a-16d; 16a', 16b'), each powder chamber (16a-16d; 16a', 16d') being provided with a powder outlet opening (19a-19d; 19a', 19b') for the discharge of raw material powder from the powder chamber (16a-16d; 16a', 16b') onto the support (12) of the apparatus for the production of workpieces by applying electromagnetic radiation or particle radiation to powder layers.