Powder Bed Additive Manufacturing With Automated Base Alignment
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Solution Overview
Problem
Current additive manufacturing methods, particularly powder bed methods like SLS, require significant manual intervention, leading to increased process time and risk of material oxidation or combustion due to exposure to ambient air.
Innovation Solution
An automated additive manufacturing method using a robot articulated arm with a sensor device to measure and correct the position of the construction platform, ensuring accurate alignment and operation within an inert gas environment to prevent oxidation and combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual work steps are used for alignment and component insertion in additive manufacturing, then the process allows for human intervention and correction, but the process time increases and the manufacturing region is exposed to ambient air causing oxidation or combustion risks
Solution Approach 1:
The system performs self-alignment through automated sensor measurement and robotic correction of the construction platform position, eliminating the need for manual alignment operations. The robot articulated arm automatically measures and corrects platform position deviations, enabling the system to self-correct without human intervention while maintaining alignment accuracy.
Solution Approach 2:
Manual mechanical alignment operations are replaced by an automated measurement and correction system comprising sensors mounted on a robot articulated arm. The system uses optical or electronic sensors to detect platform position and employs robotic actuators to automatically adjust the platform, substituting human mechanical operations with automated mechanical systems.
2Adaptability or versatility
If manual operations are performed in the manufacturing region, then flexibility and adaptability are maintained, but the powder material is exposed to ambient air increasing oxidation or combustion risks
Solution Approach 1:
The additive manufacturing process is conducted within a sealed manufacturing region filled with inert gas (such as nitrogen or argon) to displace ambient air. This inert atmosphere prevents oxidation and combustion of the powder material while the automated robotic system performs all necessary operations including measurement, platform correction, and component insertion without requiring manual access that would breach the sealed environment.
Solution Approach 2:
The system maintains continuous automated operation within the sealed inert atmosphere without interruption for manual intervention. The robot articulated arm continuously performs measurement and correction operations, and the process flows uninterrupted from powder application through platform alignment to component integration, eliminating breaks that would require opening the sealed environment and exposing powder to air.
3Extent of automation
If automated measurement and correction systems are implemented, then manual intervention is reduced and safety is improved, but device complexity increases
Solution Approach 1:
The robot articulated arm serves multiple functions within the system: it mounts and positions sensors for measurement operations, performs platform position correction through integrated actuators, and can potentially handle component insertion tasks. This multi-functional robotic system reduces the need for separate dedicated devices for each operation, managing system complexity through functional integration while maintaining high automation levels.
Data Source
AI summary
An additive manufacturing method wherein an object is manufactured by powder being applied layer-by-layer by an application device onto a base along a buildup surface and being bonded in regions to form a matrix. To provide an efficient additive powder bed method, a position of the base is checked by at least one measurement with a sensor device and the position of the base is automatically corrected at least in relation to the application device based on the at least one measurement.