Powder Dosing Module With Linked Pistons for Compact 3D Builds
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Solution Overview
Problem
Existing additive manufacturing apparatuses, such as selective laser melting (SLM) and selective laser sintering (SLS), face challenges in reducing the build volume to minimize time and material usage, especially when manufacturing small or expensive parts like gold, as they require larger build volumes and inefficient powder distribution.
Innovation Solution
A module is introduced that includes a frame with a build chamber and a dosing chamber, where the build platform and dosing piston are mechanically linked via a gear mechanism, allowing for synchronized movement and adjustable powder dosing, enabling a smaller build volume and efficient powder distribution, with a dosing chamber having a larger cross-sectional area to account for powder loss and shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the build volume is reduced to minimize time and material usage, then productivity and material efficiency are improved, but it becomes difficult to ensure sufficient powder supply and account for powder loss during the additive manufacturing process
Solution Approach 1:
The dosing chamber is designed with a larger cross-sectional area than the build chamber, extending in the horizontal dimension rather than vertically. This allows the dosing chamber to accommodate sufficient powder volume despite the reduced vertical build height, ensuring adequate powder supply for each layer while maintaining a compact overall footprint
Solution Approach 2:
The apparatus is divided into two distinct chambers: a build chamber for the additive manufacturing process and a separate dosing chamber for powder storage and delivery. This segmentation allows the dosing chamber to be optimized independently with a larger cross-sectional area, ensuring sufficient powder volume without compromising the reduced build volume
2Adaptability or versatility
If the build platform and dosing piston are independently actuated, then operational flexibility is maintained, but device complexity and control difficulty increase
Solution Approach 1:
The build platform and dosing piston are mechanically coupled through a gear mechanism, merging their actuation into a single synchronized system. This reduces control complexity by eliminating the need for independent actuation while maintaining the functional relationship between powder dosing and build platform movement
Solution Approach 2:
A gear mechanism serves as an intermediary between the build platform and dosing piston, translating vertical movement of the build platform into corresponding movement of the dosing piston. This mechanical intermediary simplifies control by automatically coordinating the two components without requiring separate control systems
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 reduced build volume and efficient powder usage, enabling faster production of small parts like dental components or jewelry by ensuring sufficient powder is supplied for each layer, while minimizing material waste and optimizing the build process.
Implementation Method 1
a mechanism mechanically linking the build platform to the dosing piston such that downward movement of the build platform in the build chamber results in upward movement of the dosing piston in the dosing chamber
Implementation Method 2
A laser beam is then scanned across areas of the powder layer that correspond to a cross-section of the object being constructed. The laser beam melts or sinters the powder to form a solidified layer
Implementation Method 3
The laser beam melts or sinters the powder to form a solidified layer
Implementation Method 4
The laser beam melts or sinters the powder to form a solidified layer
Data Source
AI summary
This invention concerns a module for insertion into an additive manufacturing apparatus. The module comprising a frame mountable in a fixed position in the additive manufacturing apparatus, the frame defining a build chamber and a dosing chamber. A build platform is movable in the build chamber for supporting a powder bed during additive manufacturing of a part. A dosing piston is movable in the dosing chamber to push powder from the dosing chamber. A mechanism mechanically links the build platform to the dosing piston such that downward movement of the build platform in the build chamber results in upward movement of the dosing piston in the dosing chamber.