Movable Fitting Element for Selective Laser Melting Powder Reduction
Solution Overview
Problem
Existing selective laser melting (SLM) and selective laser sintering (SLS) technologies face challenges in optimizing the geometry of the building chamber, leading to excessive powder usage, increased costs, and reduced efficiency due to the fixed shape of the chamber, which limits the adaptability to varying workpiece sizes and increases the workload in powder removal and screening.
Innovation Solution
The introduction of a movable fitting element that can be vertically adjusted or firmly connected to the mounting base, allowing for the adaptation of the building chamber's geometry to match the workpiece size, thereby reducing powder usage and enhancing the economic efficiency of the process by minimizing powder consumption and storage needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the building chamber has a fixed geometry, then the structural simplicity is maintained, but the adaptability to varying workpiece sizes is reduced and powder usage increases
Solution Approach 1:
The building chamber is divided into a fixed mounting base and a movable bottom element that can be independently positioned. This segmentation allows the chamber geometry to be adapted by moving the bottom element to different vertical positions, enabling customization for different workpiece sizes without redesigning the entire chamber structure.
Solution Approach 2:
The bottom element of the building chamber is made movable relative to the mounting base through linear stages. This dynamic capability allows the chamber height to be adjusted according to the specific workpiece requirements, transforming a static structure into an adaptable system that optimizes powder usage for each production scenario.
2Loss of substance
If the building chamber is sized for large workpieces, then large workpieces can be produced, but powder consumption increases for smaller workpieces
Solution Approach 1:
The movable bottom element enables dynamic adjustment of the building chamber volume to match the actual workpiece size requirements. By positioning the bottom element at appropriate heights, the chamber volume is optimized for each workpiece, minimizing excess powder while maintaining production efficiency across different scale workpieces.
Solution Approach 2:
The vertical position of the bottom element is changed as a controllable parameter to adapt the chamber geometry. By varying this positional parameter, the system optimizes the ratio of useful powder (used for workpiece) to excess powder (used for chamber filling), thereby reducing material loss without compromising productivity.
3Ease of operation
If excessive powder is used to fill the building chamber, then complete coverage is ensured, but the workload in powder removal and screening increases
Solution Approach 1:
The adjustable bottom element dynamically defines the building chamber boundary, ensuring that powder is only applied to the necessary volume. This eliminates the need to overfill the chamber with excess powder, thereby reducing the quantity of powder that requires removal and screening operations while maintaining complete coverage of the workpiece area.
4Quantity of substance
If the chamber geometry is fixed, then manufacturing simplicity is maintained, but powder storage requirements increase
Solution Approach 1:
By separating the mounting base from the movable bottom element, the system enables flexible chamber volume adjustment. This segmentation allows powder storage requirements to be optimized for each production run by adjusting the chamber volume to match the actual powder needed, reducing overall storage requirements while maintaining manufacturing simplicity through modular design.
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 allows for a significant reduction in powder usage, lower costs, reduced storage requirements, and increased production speed by customizing the chamber geometry to match the workpiece dimensions, thereby optimizing the generative manufacturing process.
Implementation Method 1
The powdery material (also referred to as 'the powder') is locally melted on the surface (by SLS) or locally melted completely (by SLM) by electromagnetic radiation (in particular laser radiation) and forms a solid layer of the material after solidification
Implementation Method 2
The powdery material is locally melted on the surface (by SLS) or locally melted completely (by SLM)
Implementation Method 3
The powdery material is locally melted on the surface (by SLS) or locally melted completely (by SLM) by electromagnetic radiation
Data Source
AI summary
In an apparatus for selective laser melting and/or laser sintering with a mounting base, that has at least one chamber, wherein the at least one chamber is a building chamber and/or a powder reservoir chamber for a powder, the saving of powder results in an increase in the possible uses of the apparatus, in that the apparatus further comprises at least one fitting element, wherein in operation, the at least one fitting element is located in the at least one building chamber, wherein in a first configuration the at least one fitting element is vertically movable relative to the main body and in a second configuration the at least one fitting element is fixedly connected to the mounting base.