Movable Protective Device for Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing processes, particularly in laser powder bed methods, the transparency of protective devices decreases due to condensation of process vapors, leading to inconsistent process results and the need for frequent replacement, disrupting continuous operation.
Innovation Solution
A movable protective device, such as a transparent glass pane, is used to separate the process chamber from the beam generating and influencing devices, with a movement mechanism that creates a turbulent boundary layer to prevent condensation, allowing for continuous operation with constant process results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective device is used to separate the beam generating device from the material processing process, then the beam generating device is protected from process impairments, but the transparency of the protective device decreases due to condensation of process vapors
Solution Approach 1:
The protective device is made movable instead of stationary, allowing it to be dynamically positioned to optimize both protection and transparency. The device can be moved to create turbulence that prevents vapor condensation while maintaining its protective function.
Solution Approach 2:
The protective device is vibrated or oscillated to prevent condensation of process vapors on its surface. This mechanical vibration creates turbulence in the boundary layer, preventing vapor accumulation and maintaining optical transparency while the device continues to protect the beam generating equipment.
2Device complexity
If the protective device is made stationary, then the structure is simple, but continuous operation is disrupted due to decreasing transparency and poor process results
Solution Approach 1:
The protective device transitions from a stationary to a movable configuration, enabling continuous operation by preventing vapor condensation. The added movement capability, while increasing complexity, ensures uninterrupted production by maintaining consistent laser transmission and process quality.
3Illumination intensity
If the protective device is moved to create turbulence, then condensation is prevented and transparency is maintained, but the device complexity increases
Solution Approach 1:
Rather than complex continuous movement systems, simple vibration or oscillation mechanisms are used to achieve the desired turbulence effect. This approach maintains transparency while minimizing the complexity of the movement mechanism.
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 enables continuous, undisturbed operation of additive manufacturing systems by reducing contamination and maintaining the transparency of protective devices, resulting in improved material quality and extended lifespan of protective components.
Implementation Method 1
the protective device moving device is designed to move the protective device in such a way that atmospheric boundary layers near a surface - in particular a surface facing the material to be processed or the processing process - turbulence are applied
Data Source
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AI summary
In order to successfully carry out an additive manufacturing process in continuous operation, the invention, according to one aspect thereof, provides a protective device (25) for use in an additive manufacturing process in which the material to be processed (14) is selectively reshaped by a material processing radiation, comprising a protective device (26) transparent to the material processing radiation (22) for separating a radiation generating device (20) for generating the material processing radiation and/or a radiation influencing device (24) provided for directing, focusing or otherwise influencing the material processing radiation from the material to be processed (14) and/or from the material processing process, and a protective device movement device (28) for moving the protective device (26) relative to an atmosphere adjacent to the protective device.