Multi-Metal Laser 3D Printing With Isolated Powder Feeding
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Solution Overview
Problem
Existing selective laser melting apparatuses in China are limited to forming single materials, and changing powder types disrupts continuity, leading to performance issues and restricted applications, with existing multi-material solutions facing challenges in powder recovery and feeding.
Innovation Solution
A multi-metal material build device integrating a powder feeding mechanism and spreading mechanism, enabling separate recovery of different metal powders and allowing for integrated rapid forming of multiple materials, with a design that avoids occupying the build chamber space and includes bidirectional powder spreading for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a chamber is opened to change powder in existing selective laser melting apparatuses, then different materials can be formed, but the continuity of forming is affected and performance is compromised
Solution Approach 1:
The build chamber is segmented into multiple isolated powder containment regions (first powder container, second powder container, etc.) that can be independently sealed. Each region contains different metal powders and can be independently accessed through separate charging ports, allowing material substitution without opening the main build chamber and disrupting the forming process continuity.
2Productivity
If existing multi-material solutions use rotary build cylinder and rotary powder cylinder mechanisms, then working efficiency is improved, but the size of formed part is limited and recovered powder material is likely to be contaminated
Solution Approach 1:
The invention transitions from horizontal rotary cylinder mechanisms to a vertical build chamber configuration with multiple powder containers arranged in different spatial positions. The build platform moves vertically through the chamber, and powder is delivered from above through dedicated charging ports, enabling larger part dimensions while maintaining multi-material capability and preventing powder cross-contamination through vertical separation of material storage and processing zones.
3Adaptability or versatility
If powder spreading mechanism and feeding mechanism are integrated in existing designs, then multi-material forming is enabled, but the powder feeding pipe is pulled during operation causing air leakage and dust emission
Solution Approach 1:
A sealed powder delivery system is implemented where inert gas pressure serves as an intermediary to transport powder from storage containers to the build chamber through sealed conduits. The powder feeding pipe is properly supported and sealed throughout its path, preventing air leakage and dust emission while enabling reliable multi-material powder delivery to the build zone.
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 the formation of integrated parts with multiple materials, avoids cross-pollution, saves material resources, reduces machining costs, and expands the application field by overcoming the limitations of single-material formation.
Implementation Method 1
A high-energy laser beam serves as a heat source to melt, overlap, and stack powder feedstack point by point, track by track, and layer by layer
Implementation Method 2
selective laser melting (SLM) is based on a principle of 'discrete+stack'. A high-energy laser beam serves as a heat source to melt, overlap, and stack powder feedstack
Data Source
AI summary
Disclosed in the present disclosure are a multi-metal material build device using laser three-dimensional printing. The multi-metal material build device includes an optical path system, a base plate, a powder collecting module, a left vertical plate, a right vertical plate, a powder falling module, a powder feeding mechanism, a slide rail, a slide connection block, a rear scraper, an L-shaped bracket, a powder storage strip and a front scraper, where the base plate, the left vertical plate and the right vertical plate form a build chamber, the powder collecting module is located at a front end below the base plate, the powder falling module and the powder feeding mechanism are located at a rear side above the base plate, and the powder feeding mechanism is located behind the powder falling module.