Movable Powder Tray and Injector for Precise AM Powder Distribution
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Solution Overview
Problem
Current additive manufacturing machines face challenges in managing powder efficiently, including the need for simplified cleaning, accurate batch identification, reduced powder usage, minimized manufacturing time, decreased contamination, and lower recycling costs, due to excess powder usage and inefficient powder distribution.
Innovation Solution
The implementation of a horizontal working plane with a movable powder spreading device and a transverse slide system that allows for precise powder deposition, enabling adjustable powder distribution, easy cleaning, and the use of multiple powder dispensing systems to optimize powder usage and reduce contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a traditional powder distribution system with a fixed pouring arm is used, then the powder can be distributed over the work surface, but the amount of powder immobilized is much greater than necessary, increasing manufacturing costs
Solution Approach 1:
The patent applies the dynamics principle by making the receiving slide movable along the transverse direction. The slide can be positioned at different locations depending on the part geometry, allowing the powder distribution system to adapt dynamically to different manufacturing needs. This resolves the contradiction by enabling precise powder delivery only where needed, reducing immobilized powder while maintaining distribution capability.
Solution Approach 2:
The patent implements local quality by allowing the receiving slide to be positioned at specific locations corresponding to the actual part dimensions. Instead of distributing powder over the entire work surface, the system delivers powder locally only to the region where the part will be manufactured. This reduces the quantity of powder immobilized while maintaining adequate distribution for the specific part being produced.
2Manufacturing precision
If excess powder is used to ensure complete coverage of the target surface, then the powder layer appropriately covers the work surface, but the amount of powder immobilized increases significantly
Solution Approach 1:
The patent applies local quality by positioning the receiving slide to match the actual part dimensions and geometry. The powder is distributed only over the specific region where coverage is needed, rather than uniformly across the entire work surface. This ensures manufacturing precision for the part while minimizing the quantity of powder immobilized in unnecessary areas.
Solution Approach 2:
The movable receiving slide enables the system to adapt its powder distribution region dynamically based on the part being manufactured. By adjusting the slide position, the system maintains precise coverage where needed while reducing powder usage in areas where no part is being produced, resolving the contradiction between coverage quality and powder quantity.
3Adaptability or versatility
If a fixed pouring arm with length corresponding to the spreading device is used, then powder can be dispensed over the work surface, but the powder distribution cannot be adjusted for different part dimensions
Solution Approach 1:
The patent implements dynamics by making the receiving slide movable along the transverse direction, allowing the powder distribution system to adapt to different part dimensions and geometries. This single degree of freedom provides the necessary adaptability without significantly increasing device complexity, as the slide moves along an existing trajectory within the manufacturing chamber.
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 facilitates accurate powder metering, reduces manufacturing time, minimizes unnecessary powder usage, and decreases contamination, thereby lowering costs and improving the overall efficiency of the additive manufacturing process.
Implementation Method 1
a laser beam, makes it possible to form, in the powder layer, a solid corresponding to the slice of the part to be manufactured
Implementation Method 2
a roll or a scraper, moving transversely to the powder line and thus providing for the spreading of the powder
Data Source
AI summary
A machine is provided for the additive manufacture of a part by complete or partial selective melting of a powder, the machine including: a horizontal working plane; at least one spreading device; at least one system for dispensing powder over the working plane comprising at least one slide for receiving powder and at least one powder injector, the receiving slide being movable in translation, with respect to the working plane, and the injector being positioned above the receiving slide, so as to dispense powder over the receiving slide which is moving between a retracted position and a deployed position.