Movable Chamber Separation Device for Additive Manufacturing
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Solution Overview
Problem
Existing additively manufacturing apparatuses face challenges in efficiently separating sub-regions within the process chamber to effectively guide off residues during the selective irradiation and consolidation of build materials, as the separation is limited by the need for the tool carrier to access the build plane and the inefficiency of gas flow in larger volumes.
Innovation Solution
A movable and/or deformable chamber separation device creates a passageway between sub-regions, allowing the tool carrier to move while maintaining a sealed volume for efficient gas flow and residue removal, with the separation element opening only when necessary to facilitate tool carrier movement and closing during irradiation to enhance gas stream effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the process chamber is entirely separated into sub-regions to improve residue removal efficiency, then the volume for process gas flow is reduced, but the tool carrier cannot access the build plane
Solution Approach 1:
The process chamber is divided into multiple sub-regions (first sub-region for irradiation, second sub-region for tool carrier access) separated by separation elements. This segmentation allows residue removal to be optimized in the irradiation zone while maintaining tool carrier accessibility through dedicated access zones and passageways.
Solution Approach 2:
The separation elements are designed to be movable or deformable, transitioning between positions that either separate or connect sub-regions. During irradiation, separation elements create sealed compartments for efficient residue removal; during tool carrier operations, they open passageways to allow access to the build plane.
2Productivity
If the process chamber volume is reduced to improve gas flow efficiency, then residue removal is enhanced, but the tool carrier movement is constrained
Solution Approach 1:
The chamber is segmented into functional zones with optimized volumes for gas flow, while tool carrier movement is facilitated through dedicated passageways and access regions that maintain adequate space for operation without compromising overall gas flow efficiency.
Solution Approach 2:
The design utilizes three-dimensional spatial arrangement where separation elements create vertical and horizontal zoning. Tool carrier movement occurs in designated access dimensions while irradiation occurs in separated processing dimensions, allowing both functions to coexist with optimized gas flow characteristics.
3Ease of operation
If separation elements are made movable and deformable to create passageways for tool carriers, then tool carrier accessibility is improved, but the sealing effectiveness for gas flow is reduced
Solution Approach 1:
Separation elements dynamically transition between sealed and open states. During irradiation, they maintain sealed positions for effective gas flow and residue removal. During tool carrier operations, they deform or move to create passageways, then return to sealed positions, ensuring both accessibility and sealing effectiveness are achieved at appropriate times.
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 improves the separation of sub-regions, allowing for more efficient guidance of residues and optimized gas flow, reducing wear and ensuring consistent process parameters by minimizing the volume of the irradiated region and enhancing the use of the gas stream for residue removal.
Implementation Method 1
selective irradiation and consolidation of layers of a powdered build material by means of an energy beam
Implementation Method 2
A respective apparatus can be a selective laser sintering apparatus, a selective laser melting apparatus or a selective electron beam melting apparatus
Implementation Method 3
The gaseous fluid stream is capable of being charged with non-consolidated particulate build material, particularly smoke or smoke residues generated during operation of the apparatus
Implementation Method 4
the separation element is movable between at least a first and a second position, wherein the separation element creates a passageway between the first and the second sub-region
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Apparatus (1, 23, 27, 30) for additively manufacturing of three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3) which can be consolidated by means of an energy beam, whereby the apparatus (1, 23, 27, 30) comprises at least one process chamber (4) with at least one chamber separation device (5, 24, 28, 31) separating a process region (6) into a first sub-region (7) and a second sub-region (8) of the process chamber (4), wherein the chamber separation device (5, 24, 28, 31) comprises at least one separation element (9, 29, 31) that is moveable and/or deformable, wherein the separation element (9, 29, 31) is configured to create a passageway (18) between the first and the second sub-region (7, 8) for at least one tool carrier (19).