Additive manufacturing machine and method with variable powder dispensing assembly
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Solution Overview
Problem
Large format additive manufacturing systems face issues with inconsistent dosing, leading to failed builds and increased costs due to underdosing or overdosing of additive powder.
Innovation Solution
A powder dispensing assembly with a housing and interchangeable plates having different discharge orifice geometries, allowing for adjustable dosing rates, and a dosing rate measurement device to monitor and adjust the powder flow in real-time, ensuring consistent dispensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed discharge orifice geometry is used in the powder dispensing assembly, then the device structure is simple, but the dosing rate cannot be adjusted leading to inconsistent dosing
Solution Approach 1:
The powder dispensing assembly incorporates interchangeable plates with different discharge orifice geometries, allowing the system to dynamically adapt the dosing rate by swapping plates. This resolves the contradiction by making the previously static orifice geometry changeable, enabling dosing consistency through selection of appropriate plates while maintaining relatively simple device structure.
Solution Approach 2:
The invention changes the physical parameter of the discharge orifice geometry by providing multiple plates with different geometries. This allows the dosing rate parameter to be adjusted by selecting the appropriate plate, thereby achieving consistent dosing without requiring complex control mechanisms.
2Reliability
If the dosing rate is not monitored and adjusted, then the system operation is simple, but underdosing or overdosing occurs leading to failed builds
Solution Approach 1:
The powder dispensing assembly includes a dosing rate measurement device that provides feedback on the actual dosing rate. This feedback mechanism allows the system to monitor and adjust the dosing rate in real-time, ensuring consistent powder delivery and preventing underdosing or overdosing that would lead to build failures.
3Manufacturing precision
If inconsistent dosing occurs, then material usage is reduced (underdosing) or increased (overdosing), but build quality deteriorates and costs increase
Solution Approach 1:
The dosing rate measurement device enables the powder dispensing assembly to self-monitor and self-adjust the dosing rate, ensuring accurate powder deposition. This self-regulating mechanism prevents both underdosing (which would compromise build quality) and overdosing (which would waste material), thereby optimizing additive powder usage while maintaining high manufacturing precision.
Data Source
AI summary
A powder dispensing assembly for an additive manufacturing machine is provided. The powder dispensing assembly includes a housing that defines a powder reservoir that receives additive powder; a first plate removably connectable to the housing, the first plate defining a first discharge orifice having a first discharge orifice geometry; and a second plate removably connectable to the housing, the second plate defining a second discharge orifice having a second discharge orifice geometry different than the first discharge orifice geometry, wherein with the first plate connected to the housing, the additive powder flows out of the first discharge orifice at a first dosing rate, and wherein with the second plate connected to the housing, the additive powder flows out of the second discharge orifice at a second dosing rate different than the first dosing rate.