3D Powder Bed Preheating Zones to Reduce Pre-Sintering
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Solution Overview
Problem
Existing three-dimensional shaping devices pre-heat the entire powder bed uniformly, leading to the generation of pre-sintered bodies in regions that do not configure the shaped object, which prolongs processing time and complicates continuous shaping.
Innovation Solution
A three-dimensional shaping device that divides the powder bed into multiple small regions, allowing for differential temperature control by a pre-heating unit, where regions to be irradiated with an energy beam are heated to a higher temperature than those not intended for irradiation, thereby reducing pre-sintered body formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire powder bed is pre-heated at a uniform temperature, then the powder material is adequately prepared for shaping, but pre-sintered bodies are generated in regions that do not configure the shaped object, prolonging processing time
Solution Approach 1:
The pre-heating unit is divided into multiple heating zones with different temperature settings. Regions corresponding to the shaped object are heated to a first temperature sufficient for shaping preparation, while regions not configuring the shaped object are heated to a second temperature lower than the first temperature. This prevents pre-sintering in non-shaping regions and reduces processing time.
2Reliability
If the entire powder bed is pre-heated at a uniform temperature, then the powder material is adequately prepared for shaping, but it becomes difficult to smoothly continue shaping processing of continuous shaped objects
Solution Approach 1:
Different temperature zones are established in the pre-heating unit corresponding to different regions of the powder bed. The region where the shaped object will be formed is maintained at a higher temperature for adequate shaping preparation, while surrounding regions are kept at lower temperatures to prevent pre-sintering, enabling smooth continuous processing.
3Manufacturing precision
If the pre-heating temperature is increased to ensure adequate preparation, then shaping quality improves, but pre-sintered bodies are generated more readily in non-irradiated regions
Solution Approach 1:
The pre-heating unit implements spatially varying temperature distribution with multiple heating zones. Regions corresponding to the shaped object receive higher temperatures for quality shaping preparation, while regions not configuring the shaped object receive lower temperatures that prevent pre-sintering, eliminating the harmful effect while maintaining shaping quality.
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 enhances processing efficiency by minimizing pre-sintered body generation in non-irradiated regions, allowing for faster and more reliable shaping of three-dimensional objects.
Implementation Method 1
a pre-heating unit disposed downstream of the supply unit in the rotation direction and capable of pre-heating each of a plurality of regions in the powder bed at different temperatures
Implementation Method 2
an irradiation unit disposed downstream of the pre-heating unit in the rotation direction and configured to irradiate at least a part of the pre-heated powder bed with an energy beam
Data Source
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AI summary
A shaping device includes a table, a forming unit that forms a shaped object, and a controller that controls an operation of the forming unit. The table rotates in a rotation direction. The forming unit has a feeder configured to form a powder bed, a heater capable of pre-heating each of a plurality of regions in the powder bed at different temperatures, and a beam source configured to irradiate the pre-heated powder bed with an energy beam. The controller includes a region division unit configured to divide the powder bed into a plurality of small regions, a region setting unit configured to set a small region including an irradiation scheduled portion to be irradiated with the energy beam by the beam source as a first region and set at least one small region among other small regions that have not been set as the first region as a second region, and a heater control unit configured to control an output of the heater such that the first region and the second region are pre-heated at mutually different temperatures.