Powder Bed Recycling by Build Platform Tilting in 3D Printing

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Solution Overview

Problem

Powder removal and collection in powder bed fusion additive manufacturing is inefficient, often requiring manual brushing or gas-spraying, which increases delays and reduces efficiency, especially for large printed objects, and poses risks due to reactive powders and contamination concerns.

Innovation Solution

An automated system that tilts or inverts the build platform to separate the powder bed from the supporting platform, using a combination of an auger and vacuum to collect powdered materials in a hopper for reuse, while maintaining a controlled inert atmosphere to prevent oxidation and contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual brushing or gas-spraying is used for powder removal, then powder can be removed from the build platform, but the process increases delays and reduces efficiency

Engineering Contradiction:

Improveprint cycle efficiencyVSAvoiddelay time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual brushing (mechanical system) with a tilting mechanism that uses gravity to remove powder. The build platform tilts to allow powder to slide off automatically, eliminating the need for manual intervention and significantly reducing the time required for powder removal between print cycles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs gas-spraying (pneumatic system) to blow remaining powder off the build platform after tilting. This automated pneumatic cleaning system replaces manual brushing and accelerates the powder removal process, thereby improving productivity and reducing delays.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of operation

If manual powder removal is performed, then powder can be cleared, but handling large printed objects becomes difficult due to size and weight

Engineering Contradiction:

Improvepowder removal easeVSAvoidbuild platform weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent replaces manual handling of heavy build platforms with an automated tilting mechanism. The mechanism rotates the entire build platform assembly, allowing gravity to do the work of powder removal rather than requiring manual effort to move or brush powder from heavy objects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of trying to remove powder from a horizontal build platform (the conventional approach), the system inverts the build platform by tilting it at an angle. This inversion allows powder to naturally slide off due to gravity, making the process easier and eliminating the need to manually handle heavy printed objects.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If powder removal is performed in open environment, then access is easier, but reactive powders may combust and contamination may occur

Engineering Contradiction:

Improveaccess easeVSAvoidoxidation and contamination risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent performs all powder removal operations within a sealed build chamber that maintains an inert atmosphere (typically nitrogen or argon). This prevents reactive metal powders from combusting during the tilting and gas-spraying processes, and prevents oxidation and contamination of both the powder and printed objects. The inert environment is maintained throughout the automated powder removal cycle.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The sealed build chamber acts as an intermediary barrier between the external environment and the powder removal process. It allows automated tilting and gas-spraying operations to occur safely while isolating the reactive powders from oxygen and contaminants in the external environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enables efficient and automated powder recycling, reducing handling challenges and maintaining a controlled environment to prevent contamination and oxidation, thus enhancing the efficiency and safety of the additive manufacturing process.

Implementation Method 1

a vacuum inside the build chamber to move the powdered material into the storage chamber

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

The storage chamber may be sealed in an atmosphere such as air, nitrogen, argon, helium, other inert gas, or noble gas to prevent oxidation and contamination

Methodology Applied

Scientific EffectInert atmosphere:

Data Source

PatentUS11911964B2Recycling powdered material for additive manufacturing

Publication Date: 2024.02.27 SEURAT TECHNOLOGIES INC

AI summary

A method and an apparatus for collecting a powdered material after a print job in powder bed fusion additive manufacturing may involve a build platform supporting a powder bed capable of tilting, inverting, and shaking to separate the powder bed substantially from the build platform in a hopper. The powdered material may be collected in a hopper for reuse in later print jobs. The powder collecting process may be automated to increase efficiency of powder bed fusion additive manufacturing.