Movable Tool Housing for Additive Manufacturing Contamination Control
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Solution Overview
Problem
Existing additively manufacturing apparatuses for three-dimensional objects face contamination issues due to the transfer of build material and residues within the process chamber, particularly when using reactive materials, leading to increased cleaning efforts.
Innovation Solution
The apparatus incorporates a tool carrier device with a movable tool housing that allows the tool unit to retract into a sealed enclosure after interaction, preventing contamination by containing residues within the housing and reducing the need for extensive cleaning of the process chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the tool unit is moved inside the process chamber to interact with the component, then the tool unit can perform its application task, but build material is transferred into regions of the process chamber where it is not desired, leading to contamination
Solution Approach 1:
The process chamber is divided into a clean region and a contaminated region separated by a partition. The partition creates distinct zones: one where the tool unit operates cleanly and another where build material residues are contained. This segmentation allows the tool unit to move freely for application tasks while preventing contamination spread to other areas.
Solution Approach 2:
The contaminated region is extracted and isolated from the main process chamber using a partition. By separating the area where build material residues accumulate from the clean operational zones, the system enables the tool unit to perform its function without contaminating the entire process chamber, thus resolving the contradiction between mobility and contamination.
2Manufacturing precision
If reactive build material is used to achieve desired object properties, then the manufacturing precision is improved, but the contaminated regions require cleaning, increasing loss of time
Solution Approach 1:
The partition extracts and isolates the contaminated region containing reactive build material residues from the clean process chamber. This allows reactive materials to be used for precise manufacturing while the partition prevents contamination spread, minimizing the need for extensive cleaning and reducing time loss.
Solution Approach 2:
The partition creates localized quality zones within the process chamber: a clean zone for tool unit operations and a contaminated zone for residue containment. This local differentiation allows reactive build materials to be used where needed for precision manufacturing while confining contamination to a specific area that requires minimal cleaning.
3Speed
If the tool unit is positioned in a parking position inside the process chamber, then the tool unit is readily available for operation, but build material adheres to the tool unit and is transferred into regions where it is not desired
Solution Approach 1:
The partition segments the process chamber so that the tool unit's parking position is located in or near the contaminated region. This allows the tool unit to remain readily available for operation while any build material adhering to it during parking is contained within the partitioned area, preventing transfer to clean regions.
Solution Approach 2:
The partition acts as an intermediary barrier between the tool unit's parking position and the clean regions of the process chamber. This mediator allows the tool unit to park conveniently while preventing build material transfer to areas where it is not desired, thus maintaining both speed and preventing contamination.
Data Source
AI summary
Apparatus (1) for additively manufacturing of three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source, which apparatus (1) comprises a tool carrier device (2) adapted to position at least one tool unit (3) inside a process chamber (4) of the apparatus (1), wherein the tool carrier device (2) comprises at least one, in particular exchangeable, tool unit (3) that is moveable between a retracted position in which the tool unit (3) is received in a tool housing (6) enclosing the tool unit (3) and an extended position in which the tool unit (3) is at least partly extended from the tool housing (6).