Powder Bed Coating and Preheating for Precise 3D Layer Solidification
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Solution Overview
Problem
Existing additive manufacturing methods for three-dimensional objects by layer-by-layer application and selective solidification of build-up materials lack efficient control over layer application and solidification processes, leading to suboptimal component quality and reproducibility.
Innovation Solution
A manufacturing process involving a coater that applies a build material layer, followed by localized actions such as heating, introduction of absorbers/inhibitors, and partial removal of components, all controlled by a solidification device and compaction device moving behind the coater, to modify the build material properties before compaction and solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a blade is used to apply the powder layer, then the layer application is simple, but the layer thickness control and surface quality are insufficient
Solution Approach 1:
A doctor blade is introduced as an intermediary element between the powder supply and the build platform. The doctor blade serves as a mediating tool that刮s the powder layer to achieve precise thickness control and smooth surface quality, resolving the contradiction between simple application and precise control.
Solution Approach 2:
The angle of the doctor blade relative to the build platform is adjusted as a controllable parameter to optimize layer thickness and surface quality. By changing this geometric parameter, the system achieves precise layer control without requiring complex mechanical structures.
2Productivity
If the powder layer is not preheated, then the process is simpler, but the sintering time is longer and energy consumption increases
Solution Approach 1:
The powder layer is preheated before the laser sintering process begins. This preliminary thermal action reduces the time required for subsequent laser sintering and decreases overall energy consumption by starting the powder at an elevated temperature rather than ambient temperature.
3Manufacturing precision
If the powder layer is compacted heavily, then the density is higher, but the layer thickness becomes less controllable and surface quality deteriorates
Solution Approach 1:
The compaction force applied to the powder layer is precisely controlled and optimized. By adjusting this parameter, the system achieves adequate layer density while maintaining surface quality and thickness control, avoiding the extremes of insufficient or excessive compaction.
4Productivity
If the laser power is increased to speed up solidification, then the processing speed increases, but the risk of overheating and material degradation increases
Solution Approach 1:
The powder layer is preheated before laser irradiation, which reduces the temperature differential required for solidification. This allows the use of lower laser power to achieve the same solidification rate, thereby reducing the risk of overheating and material degradation while maintaining high productivity.
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 allows for precise control over the build material's properties, promoting faster temperature achievement, more accurate layer thickness, and improved mechanical properties of the manufactured object, enhancing component quality and reproducibility.
Implementation Method 1
The application of the layer of build-up material by means of the coater preferably includes drawing out the applied build-up material to form a layer according to predetermined criteria with regard to a surface extent and/or thickness and/or surface quality and/or density of the layer
Implementation Method 2
the selective solidification of the applied layer of the construction material at points that correspond to a cross section of the object to be produced, by means of a solidification device
Implementation Method 3
The local heating preferably takes place by means of induction and/or radiation
Implementation Method 4
a powder layer applied by means of a blade can be compacted by means of a roller
Data Source
Figure 1
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AI summary
A manufacturing method for the additive manufacturing of a three-dimensional object (2) by layered application and selective solidification of a building material (15), preferably a powder, includes the steps of applying a layer of the building material (15) within a building area (8) by means of a coater (16) moving over the building area (8) in a coating direction (B), selectively solidifying the applied layer of the building material (15) at locations that correspond to a cross section of the object (2) to be manufactured, by means of a solidification device, and repeating the applying and solidification steps until the three-dimensional object (2) is completed. The solidification device and/or a compacting device (50) moves over the building area (8) behind a coating unit (40) of the coater (16) in the coating direction (B). The applied layer of the building material (15) is exposed to a local effect that is confined to a region between the coating unit (40) moving over the building area (8) and the solidification device and/or compacting device (50) moving over the building area (8) behind the coating unit (40). The invention also relates to a computer program, a control device and a manufacturing device for the additive manufacturing of a three-dimensional object (2).