Movable Protection Element for Additive Manufacturing Windows
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in preventing contamination of transparent window elements during the layer-wise production of 3D articles, as prior solutions like heating elements and inert gas flows do not completely prevent fogging or contamination, especially when gaseous contaminants can deposit and burn on hot surfaces, leading to decreased output and requiring periodic cleaning or replacement of glass windows.
Innovation Solution
A movable, transparent protection element is introduced between the window element and the raw material surface, which can be exchanged without interrupting the manufacturing process. This protection element is temperature-resistant, capable of withstanding at least 100 degrees Celsius, and can be attached using electrostatic forces or suction, ensuring continuous operation and easy replacement when contaminated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a heating element is provided to increase the temperature of the exit lens, then condensation of decomposition products on the lens can be avoided, but gaseous contaminants can deposit and burn on the hot surface, accelerating contamination
Solution Approach 1:
A movable protection element (shutter) is introduced as an intermediary between the laser beam path and the window element. This shutter blocks contaminants from reaching the window element during critical phases while allowing the laser beam to pass through when positioned appropriately, thus protecting the window without requiring high temperatures that would cause contaminant burning
2Reliability
If a glass plate is used as a protective device, then the optical unit can be protected from contamination, but the glass window itself becomes susceptible to contamination during beam operation
Solution Approach 1:
The protection element is designed to be movable rather than static. It can dynamically adjust its position to block contaminants when needed while allowing the laser beam to pass through during operation, providing adaptive protection that responds to different operational phases of the additive manufacturing process
3Object-generated harmful factors
If the shutter is closed only during lowering or lifting of the frame, then fumes can be discharged, but the glass window remains unprotected during beam operation
Solution Approach 1:
The protection element is positioned and configured in advance to cover the window element before the laser beam operation begins. This preliminary positioning ensures that the window is protected from contaminants throughout the entire beam operation process, not just during frame movement phases
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
The solution effectively prevents contamination of the window element by redirecting contaminants away from the energy beam path, maintaining the transparency and efficiency of the additive manufacturing process, reducing the need for frequent cleaning or replacement of components and enhancing productivity by minimizing thermal stress and energy consumption.
Implementation Method 1
The protection element can be attached using electrostatic forces or suction
Implementation Method 2
The protection element is temperature-resistant, capable of withstanding at least 100 degrees Celsius
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An additive manufacturing device (1) comprises a beam generation unit (3), a raw material container (5) and a raw material supply unit (4). A window element (2) is provided for transmission of an energy beam (8) emittable by the beam generation unit (3) to the raw material container (5) for manufacturing a solid article from a plurality of raw material layers, whereby the raw material comprises a powder. The raw material container contains a raw material (6) arranged in a plurality of raw material layers arranged upon each other, such that an uppermost raw material layer including a raw material surface (7, 17) is exposed to the energy beam (8). The window element (2) comprises a first surface (31) and a second surface (32), whereby the first surface (31) faces the beam generation unit (3) and the second surface (32) faces the raw material surface (7, 17). The second surface (32) is at least partially covered by a protection element (70). The protection element (70) is transparent for the energy beam (8) such that in operation, the energy beam (8) passes through the protection element (70).