Multi-Element Re-Coating Device for Additive Manufacturing
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Solution Overview
Problem
Current build material application strategies for additive manufacturing are inefficient, particularly in the application of build material layers that need to be selectively irradiated and consolidated by energy beams, as they often rely on a single re-coating element moving in repetitive paths which can lead to suboptimal material distribution and processing efficiency.
Innovation Solution
A build material application device with at least two separate re-coating elements, each supported in distinct motion paths, allowing for efficient application of build material in a build plane by moving across the plane in specific paths for material deposition and return paths for non-deposition, enabling precise control and distribution of build material layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single re-coating element is used to apply build material across the build plane, then the device complexity is reduced, but the productivity and efficiency of build material application deteriorates due to repetitive motion paths and suboptimal material distribution
Solution Approach 1:
The build material application device is segmented into multiple independent re-coating elements (at least two), each capable of moving along its own motion path. This segmentation allows parallel material application across different regions of the build plane, significantly improving productivity while distributing the complexity across modular components rather than a single complex element
2Loss of time
If a single re-coating element moves repeatedly across the build plane in track motion, then the device complexity is minimized, but the loss of time increases due to frequent back-and-forth motion and non-productive return trips
Solution Approach 1:
The motion paths of the re-coating elements are extended from simple linear tracks to multi-dimensional paths that include both productive build material application segments and non-productive return segments in different spatial dimensions. This allows elements to utilize otherwise wasted return trips for additional material application tasks, converting time loss into productive action
3Manufacturing precision
If a single re-coating element is used, then the ease of operation is maintained, but the manufacturing precision of build material layers deteriorates due to suboptimal material distribution
Solution Approach 1:
Different re-coating elements are assigned to specific regions or zones of the build plane, with each element optimized for its local area. This allows tailored material application strategies for different regions, improving layer uniformity and manufacturing precision while keeping each individual element relatively simple in design
Data Source
AI summary
Build material application device (6) for an apparatus (1) for additively manufacturing three-dimensional objects (2), the build material application device (6) being adapted to apply an amount of build material (3) in a build plane (BP) of a respective apparatus (1), the build material application device (6) comprising: a first build material application element (6a), the first build material application element (6a) being moveably supported in a first motion path (MP1) in which the first build material application element (6a) is moved across the build plane (BP), and in a second motion path (MP2) in which the first build material application element (6a) is not moved across the build plane (BP); a second build material application element (6b), the second build material application element (6b) being moveably supported in a first motion path (MP1) and in a second motion path (MP2).