Partial Sintering of AM Powder to Reuse Undersized Particles
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Solution Overview
Problem
Existing additive manufacturing processes face inefficiencies due to the production of undersized powder particles that require additional steps like remelting or pressing, increasing time, energy, and costs for recycling.
Innovation Solution
A method and system for partially sintering undersized powder particles to increase their size within a controlled temperature/time profile, followed by sieving or milling to achieve desired dimensions suitable for additive manufacturing, without forming a full-strength network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If powder particles are heated to high temperature for complete sintering to form near full density solid parts, then particle strength and density are improved, but processing time increases to many hours or days
Solution Approach 1:
The patent applies partial sintering by heating powder particles to high temperature for a limited duration (minutes rather than hours or days), achieving sufficient particle bonding and size increase without completing the full sintering process. This partial action resolves the contradiction by providing adequate particle strength for AM feedstock while dramatically reducing processing time.
2Manufacturing precision
If undersized powder particles are remelted or pressed into solid parts and then recycled back into powder making process, then particle size requirement is met, but extra processing steps and energy consumption are required
Solution Approach 1:
The patent performs preliminary sintering of undersized powder particles during the main powder production process, transforming them into appropriately sized particles before the particles would need to be remelted or pressed. This preliminary action eliminates the need for subsequent energy-intensive remelting or pressing operations, directly resolving the contradiction between particle size control and energy consumption.
3Quantity of substance
If complete sintering is performed to create near full density solid parts, then particle density is improved, but the particles become too large and dense for use as feedstock material in additive manufacturing
Solution Approach 1:
The patent deliberately stops the sintering process before completion, creating particles that are partially sintered rather than fully sintered. This partial action produces particles with adequate density and strength for AM feedstock while preventing the formation of overly large and dense particles that would be unsuitable for the intended application.
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
This approach efficiently transforms undersized powder particles into larger, usable sizes, reducing processing time and costs while maintaining the powder's integrity as individual particles, suitable for additive manufacturing applications.
Implementation Method 1
Sintering is the process where powder particles are heated to a high temperature below their melting point, and solid diffusion occurs. During the sintering process, particles located next to each other will fuse, or sinter, together where they are in contact.
Data Source
AI summary
A system for creating a second quantity of sinterable powder particles which have sizes falling within a second size range, from a first quantity of sinterable powder particles having sizes falling within a first size range, and where the sizes of the powder particles in the second size range are all larger than those in the first size range. In one embodiment the system has a heating component responsive to a predetermined temperature/time heating profile, which heats the first quantity of powder particles using the temperature/time heating profile, to cause partial sintering of the powder particles, which creates a new plurality of powder particles which have an increased dimension. A movement component is incorporated to at least one of separate the new powder particles from remaining ones of the powder particles of the first quantity of powder particles, or to further process the new plurality of powder particles, such that the new plurality of powder particles represents the second quantity of sinterable powder particles.