Additive Manufacturing Apparatus with Movable Build Units

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Solution Overview

Problem

Current additive manufacturing technologies for metal parts require large amounts of powder, leading to weight and management issues, especially in large component production, as unused powder complicates elevator systems and chamber pressure, and is unmanageable in large bed systems.

Innovation Solution

An additive manufacturing apparatus with movable build units along a defined path over a build chamber, incorporating a powder dispenser, applicator, and directed energy source to fuse the powder, allowing for layer-by-layer construction of parts with reduced powder usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional powder bed technologies are used for additive manufacturing, then high resolution capabilities are achieved, but large amounts of powder (over 130 kg) are required which complicates elevator systems, increases weight, and creates management problems

Engineering Contradiction:

Improveresolution capabilitiesVSAvoidpowder load

Core Design Contradiction:

Measurement precisionVSQuantity of substance

Solution Approach 1:

The build chamber is divided into multiple zones with selective powder deposition. Instead of filling the entire build chamber with powder, the system deposits powder only in specific regions where parts will be manufactured, segmenting the powder distribution to reduce overall powder quantity while maintaining resolution capabilities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system applies different powder distribution strategies to different regions of the build chamber. Powder is deposited locally only where needed for part construction, rather than uniformly throughout the entire chamber, optimizing powder usage while maintaining the necessary resolution for high-quality parts.

Inventive Principle:

Principle #3Local quality

2Productivity

If large powder beds are used for large component production, then parts can be manufactured, but unused powder becomes unmanageable and adds weight to elevator systems

Engineering Contradiction:

Improvelarge component productionVSAvoidpowder management

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system extracts and removes unused powder from the build chamber after part construction is complete. This extraction mechanism eliminates the management burden of unused powder, preventing it from accumulating and adding weight to elevator systems, while still enabling large component production during the build process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The powder distribution system is made dynamic, allowing real-time adjustment of powder deposition based on part construction requirements. This dynamic control enables the system to adapt powder usage to actual part needs, reducing unused powder accumulation and simplifying overall powder management during large component production.

Inventive Principle:

Principle #15Dynamics

3Productivity

If conventional powder bed systems are used, then parts can be built, but chamber pressure problems and seal complications arise due to large powder quantities

Engineering Contradiction:

Improvepart build capabilityVSAvoidseal and pressure management

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system uses partial powder deposition rather than filling the entire build chamber. By applying powder only where parts will be constructed rather than excessively filling the whole chamber, the system reduces the total powder quantity, thereby simplifying seal requirements and chamber pressure management while still enabling complete part build capability.

Inventive Principle:

Principle #16Partial or excessive action

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 approach enables efficient production of large parts with reduced powder consumption, simplifying the management of unused powder and minimizing weight and pressure issues, while maintaining high resolution capabilities.

Implementation Method 1

a directed energy source configured to fuse the scraped powder

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

using the one or more build units to direct a beam from a directed energy source to fuse the powder

Methodology Applied

Scientific EffectEnergy beam fusion: Laser Beam Welding

Data Source

PatentUS11478983B2Additive manufacturing apparatus and method for large components

Publication Date: 2022.10.25 GENERAL ELECTRIC CO

AI summary

An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.