Modular Powder Bed Containment Walls for Low-Waste DMLM Builds

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Solution Overview

Problem

Conventional direct metal laser melting (DMLM) systems have non-customizable powder bed containment walls, leading to object size constraints and significant powder waste due to the use of disposable containment walls constructed from weldable powder.

Innovation Solution

A customizable powder bed containment system featuring interlinkable containment walls that can be mechanically coupled to a build plate and selectively raised by actuators, allowing for the creation of a customized powder bed that conforms to the shape of the object being manufactured, reducing powder waste and enabling reconfiguration for various object sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fixed powder bed containment walls are used in conventional DMLM systems, then the system can maintain structural stability, but the system suffers from non-customizable powder bed containment and object size constraints

Engineering Contradiction:

Improvecustomizability of powder bed containmentVSAvoidcomplexity of containment wall system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The containment wall system is divided into multiple modular segments that can be independently configured. Each segment can be selectively positioned and interconnected to form different powder bed geometries, enabling customization for various object sizes and shapes while maintaining structural integrity through standardized connection interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The containment walls are designed with movable and adjustable components that allow dynamic reconfiguration of the powder bed geometry. The walls can be positioned at different heights and angles, and the entire structure can be adapted between manufacturing cycles to match the specific requirements of different objects, transitioning from static fixed walls to dynamic customizable structures.

Inventive Principle:

Principle #15Dynamics

2Loss of substance

If disposable powder bed containment walls constructed from weldable powder are used, then the powder bed can be contained effectively, but significant powder waste occurs and cycle time increases

Engineering Contradiction:

Improvepowder wasteVSAvoidease of containment wall construction

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

Instead of discarding the containment walls after each use, the modular walls are designed to be recovered and reused across multiple manufacturing cycles. The walls are removed from the completed object, cleaned of residual powder, and prepared for reuse in the next manufacturing cycle, significantly reducing powder waste and eliminating the need to reconstruct containment walls from scratch each time.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The invention inverts the disposable concept by creating durable, reusable containment walls that replace the traditional disposable approach. Rather than using cheap, single-use walls made from weldable powder, the system employs more durable modular walls that can be reused many times, transforming a disposable resource into a reusable asset that reduces overall material consumption.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If conventional fixed containment walls are used, then the system structure is simple, but the system cannot accommodate objects of different shapes and sizes efficiently

Engineering Contradiction:

Improveaccommodation of various object sizesVSAvoidmanufacturing cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The modular containment walls are pre-configured with standardized connection interfaces and mounting features that allow rapid assembly and reconfiguration. Before each manufacturing cycle, the walls can be quickly adjusted and interconnected to match the required object geometry, eliminating time-consuming custom fabrication while maintaining adaptability to different object sizes and shapes.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10967459B2Customizable powder bed containment systems for use with direct metal laser melting systems

Publication Date: 2021.04.06 GENERAL ELECTRIC CO

AI summary

A customizable powder bed containment system for use with a direct metal laser melting (DMLM) system includes a plurality of interlinkable containment walls mechanically couplable on a build plate of the DMLM system as well as mechanically coupleable to another interlinkable containment wall of the plurality of interlinkable containment walls, and at least one actuator mechanically coupled to at least one interlinkable containment wall of the plurality of interlinkable containment walls. The at least one actuator is operable to selectively raise the at least one interlinkable containment wall of the plurality of interlinkable containment walls axially relative to a build surface of the build plate.