3D Printing Gas Flow Layout for Powder Bed Smoke Removal

Solution Overview

Problem

Existing additive manufacturing apparatuses face challenges in efficiently removing non-consolidated particulate build material, such as smoke or smoke residues, from the process chamber without disturbing the powder bed, especially when using high-power energy beams.

Innovation Solution

The apparatus employs a stream generating device with multiple units configured to generate a gaseous fluid stream, which efficiently removes non-consolidated particles while preventing the disturbance of build material particles from the powder bed, even with high-power energy beams, by using identical or similar stream generating units operating in parallel and controlled independently or synchronously.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single stream generating device is used to remove non-consolidated particles, then the device complexity is low, but the removal efficiency is insufficient when using high-power energy beams

Engineering Contradiction:

Improveremoval efficiency of non-consolidated particlesVSAvoidcomplexity of stream generating device

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The stream generating device is divided into multiple independent stream generating units (first, second, and third units) that operate in parallel. Each unit generates a gaseous fluid stream with specific streaming properties, allowing the system to achieve higher overall removal efficiency while maintaining modular complexity management.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If high-power energy beams are used for irradiation, then the consolidation quality is improved, but non-consolidated particles are not efficiently removed

Engineering Contradiction:

Improveconsolidation quality of build materialVSAvoidremoval efficiency of non-consolidated particles

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The stream generating device is divided into multiple independent stream generating units (first, second, and third units) that operate in parallel. Each unit generates a gaseous fluid stream with specific streaming properties, allowing the system to achieve higher overall removal efficiency while maintaining modular complexity management.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different stream generating units are configured with different streaming properties (velocity, flow rate, direction) to address local requirements in different regions of the process chamber. This allows optimized particle removal in high-power irradiation zones while maintaining appropriate flow characteristics in other areas.

Inventive Principle:

Principle #3Local quality

3Productivity

If strong gaseous fluid stream is used to remove particles, then the removal efficiency is improved, but build material particles are raised from the powder bed

Engineering Contradiction:

Improveremoval efficiency of non-consolidated particlesVSAvoidintegrity of powder bed

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Different stream generating units are configured with different streaming properties (velocity, flow rate, direction) to address local requirements in different regions of the process chamber. This allows optimized particle removal in high-power irradiation zones while maintaining appropriate flow characteristics in other areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The stream generating units are configured to apply partial action - using sufficient flow strength to remove non-consolidated particles in irradiated zones while keeping the flow below the threshold that would disturb consolidated particles in the powder bed. The multiple units allow distributed application of this partial action across different chamber regions.

Inventive Principle:

Principle #16Partial or excessive action

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 ensures effective removal of non-consolidated particles and maintains the integrity of the powder bed, enhancing the quality of manufactured three-dimensional objects by utilizing the enhanced power spectrum and redundancy of the stream generating device.

Implementation Method 1

a stream generating device configured to generate a gaseous fluid stream at least partly streaming through the process chamber

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

successive layerwise selective irradiation and consolidation of layers of a powdered build material which can be consolidated by means of an energy beam

Methodology Applied

Scientific EffectEnergy beam irradiation: Laser

Data Source

PatentUS11433616B2Apparatus for additively manufacturing three-dimensional objects

Publication Date: 2022.09.06 CONCEPT LASER

AI summary

Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a powdered build material (3) which can be consolidated by means of an energy beam (4), the apparatus (1) comprising a process chamber (8) and a stream generating device (9) configured to generate a gaseous fluid stream at least partly streaming through the process chamber (8), the gaseous fluid stream being capable of being charged with non-consolidated particulate build material, particularly smoke or smoke residues generated during operation of the apparatus (1), while streaming through the process chamber (8), wherein the stream generating (9) device comprises at least two separate stream generating units (13, 14) each being configured to generate a respective gaseous fluid stream.