Perforated Mesh Gripper for Automated Depowdering in Additive Manufacturing
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Solution Overview
Problem
Conventional depowdering processes in powder-based additive manufacturing are inefficient, leading to wasted material, damage to objects, machine jamming, high labor costs, and safety hazards due to manual handling and loose powder exposure.
Innovation Solution
An automated system comprising a gripper assembly with perforated mesh structures and a robotic arm for precise object extraction and depowdering, using a fluid stream to remove powder through the mesh openings while gripping the object, reducing manual intervention and powder dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual depowdering is used, then labor flexibility is maintained, but labor costs increase and safety hazards occur
Solution Approach 1:
The patent combines the object extraction function and depowdering function into a single integrated subsystem. The gripper assembly with perforated mesh structure performs both extraction from the powder bed and subsequent depowdering through fluid stream application, eliminating the need for separate manual operations and reducing overall system complexity despite automating multiple functions.
Solution Approach 2:
The perforated mesh structure of the gripper assembly allows the object to be self-depowdered during extraction. The mesh openings enable powder to pass through naturally as the object is lifted, and the integrated fluid stream system automatically cleans remaining powder without requiring additional manual intervention or complex separate depowdering equipment.
2Loss of substance
If conventional manual removal is used, then equipment simplicity is maintained, but powder material is wasted and machine parts jam
Solution Approach 1:
The perforated mesh structure of the gripper assembly extracts only the necessary function of holding the object while allowing excess powder to pass through the openings during extraction. This selective extraction approach removes the object cleanly from the powder bed without carrying excessive powder, and the integrated fluid stream system further removes remaining powder, minimizing material waste and preventing machine jamming.
3Productivity
If automated extraction system is implemented, then productivity increases, but system complexity increases
Solution Approach 1:
The patent merges the robotic extraction system and depowdering system into a single integrated subsystem controlled by one processor. The gripper assembly with perforated mesh structure serves dual purposes for both extraction and depowdering, and the fluid stream system is coordinated with the extraction motion, achieving high productivity through automation while managing complexity through functional integration.
4Object-affected harmful factors
If manual powder removal is used, then equipment simplicity is maintained, but safety hazards from loose powder exposure occur
Solution Approach 1:
The integrated automated system extracts and removes loose powder immediately after object extraction using the fluid stream system directed through the perforated mesh gripper. This rapid extraction of harmful loose powder from the workspace eliminates safety hazards associated with manual handling and exposure, while the automation contains and controls the powder removal process.
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
Significantly reduces time and labor in extracting objects, minimizes powder wastage, prevents machine jamming, and enhances safety by automating the depowdering process, allowing for efficient and controlled removal of powder from objects outside the powder bed.
Implementation Method 1
a nozzle configured to direct a fluid stream at the object while gripped by the gripper assembly such that the fluid stream can pass through openings of the perforated mesh structure
Implementation Method 2
the perforated mesh structure may include a plurality of openings that are configured to allow powder from the powder bed to flow therethrough during one or more steps of extracting the object from the powder bed
Data Source
AI summary
Systems and methods for additive manufacturing of objects are disclosed. The system includes an object builder subsystem configured to additively manufacture an object in a powder bed, an object extraction subsystem configured to extract the object from the powder bed, and a depowdering subsystem configured to remove powder from the object while the object is gripped by the gripper assembly. The object extraction subsystem includes a gripper assembly comprising two or more gripper members that each include a perforated mesh structure.