Powder Discharge Unit for Additive Manufacturing
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Solution Overview
Problem
Existing methods for generatively manufacturing three-dimensional objects by layer-by-layer application and selective solidification of powder materials face issues with the discharge of fine powder particles and slopping of fluidised powder, particularly during the acceleration or deceleration of the recoating unit.
Innovation Solution
A powder discharge unit that fluidises the building material independently in a powder container and filling chamber, with controlled gas supply and heating, prevents the discharge of fine particles and slopping by maintaining a fluidised state only within the container during movement, ensuring the recoater receives the required amount of powder continuously or in portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the powder is fluidised in the preheat module, then the powder can be evenly distributed and received by the recoating unit, but fine powder particles are discharged from the preheat module with the fluidisation medium
Solution Approach 1:
The device is divided into two separate modules: a preheat module for fluidizing and heating the powder, and a recoating unit for applying the powder layer. The preheat module contains a screen that retains the powder while allowing the fluidisation medium to pass through, preventing fine particle discharge. This segmentation allows each module to perform its specific function optimally without interfering with the other.
Solution Approach 2:
A screen is introduced as an intermediary element between the preheat module and the recoating unit. The screen acts as a filter that allows the fluidisation medium to pass through while retaining the powder particles, thus mediating between the need for powder fluidization and the need to prevent fine particle discharge.
2Speed
If the recoating unit accelerates or decelerates, then it can move across the build area to apply powder layers, but fluidised powder slops over the edge of the preheat module
Solution Approach 1:
The device is divided into two separate modules: a preheat module for fluidizing and heating the powder, and a recoating unit for applying the powder layer. The preheat module contains a screen that retains the powder while allowing the fluidisation medium to pass through, preventing fine particle discharge. This segmentation allows each module to perform its specific function optimally without interfering with the other.
Solution Approach 2:
The recoating unit is designed to be movable across the build area, allowing it to accelerate and decelerate as needed for different application requirements. The separate preheat module with its screen retains the powder during these dynamic movements, preventing slopping while allowing the recoating unit to maintain its dynamic capability.
3Productivity
If the powder is fluidised continuously, then the recoating unit can receive powder continuously, but fine powder particles are discharged continuously with the fluidisation medium
Solution Approach 1:
The device is divided into two separate modules: a preheat module for fluidizing and heating the powder, and a recoating unit for applying the powder layer. The preheat module contains a screen that retains the powder while allowing the fluidisation medium to pass through, preventing fine particle discharge. This segmentation allows each module to perform its specific function optimally without interfering with the other.
Solution Approach 2:
A screen is introduced as an intermediary element between the preheat module and the recoating unit. The screen acts as a filter that allows the fluidisation medium to pass through while retaining the powder particles, thus mediating between the need for powder fluidization and the need to prevent fine particle discharge.
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
Effectively reduces or prevents the discharge of fine powder particles and slopping, ensuring precise and efficient application of powder layers during the manufacturing process, enhancing the accuracy and quality of three-dimensional object creation.
Implementation Method 1
The powder discharge unit is configured to fluidise the building material in powder form in the powder container and in the filling chamber independently of one another
Implementation Method 2
the porous plate and/or the perforated plate comprised in the bottom of the powder discharge unit, wherein the porous plate and/or the perforated plate comprise a heating element for heating the porous plate and/or the perforated plate
Data Source
AI summary
A powder discharge unit for equipping and/or upgrading a device for generatively manufacturing a three-dimensional object by a selective layer-by-layer solidification of building material in powder form includes a powder container for receiving building material in powder form and a filling chamber for filling in building material in powder form into the powder container. The powder discharge unit is configured to fluidise the building material in powder form in the powder container and the building material in powder form in the filling chamber independently of one another.