3D Printer Platen Sections with Compressible Sheets
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Solution Overview
Problem
Three-dimensional printing systems using powder materials face high costs due to excessive powder usage and temperature control challenges during the layer-by-layer fabrication process.
Innovation Solution
The system employs an array of platen sections with compressible sheets and actuators to minimize powder usage by selectively positioning the platen sections vertically, using a powder dispenser and energy beam source to fuse layers, while maintaining a controlled build environment with a gas handling system and controller for precise operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a continuous build platform is used, then the structure is simple, but powder material is wasted at the edges and corners
Solution Approach 1:
The build platform is divided into multiple independently controllable platen sections arranged in a grid pattern. Each section can be individually lowered or raised by actuators, allowing the build surface to conform precisely to the powder bed geometry and eliminate wasted powder at edges and corners.
2Loss of substance
If the build platform is lowered to reduce powder usage, then powder consumption decreases, but temperature control becomes difficult
Solution Approach 1:
The platen sections are equipped with actuators that enable dynamic adjustment of each section's vertical position during the printing process. This allows the build platform to adaptively lower or raise sections based on real-time temperature feedback and powder consumption requirements, optimizing both material efficiency and thermal management.
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 reduces powder consumption and enhances temperature control, thereby optimizing the layer-by-layer fabrication process, improving efficiency and cost-effectiveness in three-dimensional printing.
Implementation Method 1
Each layer of powdered material is selectively fused at a build plane using an energy beam such as a laser, electron, or particle beam
Implementation Method 2
The plurality of compressible sheets fill the plurality of vertical gaps. For each facing pair of vertical surfaces, one of the compressible sheets is coupled to one of the facing vertical surfaces and slidingly engages the other of the facing vertical surfaces
Data Source
AI summary
A three-dimensional printing system includes an array of platen sections, a plurality of compressive sheets, a chassis, a plurality of actuators, a powder dispenser, and an energy beam source. The array of platen sections individually have a top surface and a plurality of vertical side surfaces intersecting the top surface. The plurality of platen sections are positioned with adjacent pairs of platen sections having a pair of the vertical side surfaces in facing relation with each other and defining a vertical gap therebetween. Thus they define a plurality of vertical gaps over the array of platen sections. The plurality of compressible sheets fill the plurality of vertical gaps. The chassis supports the array of platen sections. The plurality of actuators is for individually and vertically positioning the platen sections.