Powder Dispensing Assembly Selective Deposition Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing machines waste powder due to the need for large volumes to cover entire powder beds, as they deposit a single layer of additive powder over the entire bed, leading to inefficiencies in powder usage, especially when building larger parts.
Innovation Solution
A powder dispensing assembly with a hopper and multiple powder distribution modules, each equipped with a discharge orifice, supply gate, plunger valve, and actuator, allowing for selective and controlled dispensing of additive powder at desired locations and flow rates, reducing powder waste by enabling targeted deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a single gate is used to deposit powder over the entire powder bed, then the powder bed can be covered, but a very large volume of powder is needed resulting in wasted powder
Solution Approach 1:
The single gate is divided into multiple gates (first gate, second gate, third gate, fourth gate) arranged in a matrix pattern across the powder bed. Each gate independently dispenses powder to a specific region, eliminating the need to cover the entire powder bed with powder and significantly reducing powder waste.
Solution Approach 2:
Each gate is equipped with its own flow control mechanism (screw mechanism, chain drive, and gear system) to independently regulate powder flow rate. This allows precise control of powder deposition in each local region, ensuring powder is deposited only where needed at the required amount.
2Quantity of substance
If a large volume of powder is used to cover the entire powder bed, then complete coverage is achieved, but powder efficiency decreases
Solution Approach 1:
The powder bed is divided into multiple zones served by different gates. Powder is supplied only to the zones where parts are being built, rather than covering the entire powder bed. This segmented approach reduces the total quantity of powder needed while maintaining complete coverage of required areas.
Solution Approach 2:
Instead of applying powder uniformly across the entire powder bed (excessive action), the system applies powder only to the specific regions where parts are being manufactured (partial action). The four gates collectively cover only the necessary areas, eliminating excessive powder usage.
3Adaptability or versatility
If conventional powder hoppers are used, then simple structure is maintained, but selective powder deposition capability is limited
Solution Approach 1:
The dispensing mechanism is segmented into multiple independent gate units, each capable of selective powder deposition. Each gate can be independently controlled to deposit powder in its designated region, providing spatial selectivity across the powder bed.
Solution Approach 2:
Each gate is equipped with a dynamic flow control mechanism including a screw that can be rotated by a chain drive and gear system. This allows real-time adjustment of powder flow rate and deposition amount, enabling adaptive control of powder dispensing according to manufacturing requirements.
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 allows for precise and efficient deposition of additive powder, reducing waste and enabling the building of larger parts with minimal excess powder usage, enhancing the versatility and efficiency of additive manufacturing processes.
Implementation Method 1
A plunger valve is movably mounted over the discharge orifice... to selectively dispense a flow of additive powder
Data Source
AI summary
A powder dispensing assembly for an additive manufacturing machine includes a hopper defining a powder reservoir for receiving additive powder and a plurality of powder distribution modules operably coupled with the hopper. The powder distribution modules include a powder distribution body defining a discharge orifice and a supply gate that fluidly couples the powder reservoir to the discharge orifice. A plunger valve is movably mounted over the discharge orifice and an actuator moves the plunger valve between an open position and a closed position to selectively dispense a flow of additive powder.