Powder Feed Switching Near the Nozzle for Faster 3D Printing
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Solution Overview
Problem
Current 3D printing technologies using laser metal deposition (LMD) face challenges with substantial powder response time and material wastage due to the distance between the powder distributor and nozzle, leading to inefficiencies in powder flow control and increased material consumption.
Innovation Solution
A switching system for 3D printing facilities that includes a movable distributor allowing for quick interruption and reestablishment of powder flow, enabling efficient recycling of unused powder and minimizing response time by positioning the distributor close to the nozzle, with multiple conduits and positions for handling multiple powders and gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the distributor is positioned far from the nozzle for bulk and maintenance reasons, then the system is easier to maintain and fill, but the powder response time increases substantially (about 10 seconds)
Solution Approach 1:
The system is divided into two functional zones: a remote bulk storage distributor for easy maintenance and filling, and a local temporary storage unit positioned near the nozzle for rapid powder delivery. This segmentation allows the maintenance-friendly remote distributor to continue its function while the nearby temporary storage provides the fast response needed for precise powder delivery control.
Solution Approach 2:
A temporary powder storage unit acts as an intermediary between the remote bulk distributor and the nozzle. This intermediary component receives powder from the distant distributor and quickly delivers it to the nozzle, mediating the conflict between remote positioning (for maintenance ease) and proximity (for fast response).
2Productivity
If a simple solenoid valve is used to interrupt powder flow, then the powder flow can be stopped on demand, but the dispensing channels become plugged when not ventilated
Solution Approach 1:
The solenoid valve is extracted from the main powder dispensing path and relocated to the exhaust channel. This removes the valve from the high-risk area where plugging occurs, while still enabling flow control through its position in the exhaust path. When the valve closes, it stops powder flow indirectly by blocking the exhaust path that would otherwise allow continuous flow.
Solution Approach 2:
The exhaust channel serves as an intermediary path that mediates between the powder flow control requirement and the plugging prevention requirement. By placing the solenoid valve in this intermediate exhaust channel rather than directly in the powder dispensing channel, the system achieves flow control without exposing the main dispensing path to plugging risks.
3Loss of time
If the carrier gas flow rate is increased to reduce response time, then powder delivery speed improves, but powder wastage increases
Solution Approach 1:
The temporary storage unit is pre-filled with powder before it is needed at the nozzle. This preliminary action of storing powder close to the delivery point eliminates the need for high-velocity gas flow during actual deposition, as the powder is already in position and can be delivered with minimal gas assistance, thereby reducing both response time and powder wastage.
Solution Approach 2:
The system dynamically adjusts carrier gas flow rates based on operational phase: higher flow rates are used only during the brief transition periods when powder needs to be moved between storage locations, while lower flow rates are used during steady-state deposition to minimize powder wastage. The temporary storage unit enables this dynamic approach by decoupling the transport phase from the deposition phase.
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 significantly reduces powder wastage and response time, allowing for precise control over powder flow, thereby enhancing the efficiency and cost-effectiveness of the 3D printing process while maintaining mechanical properties of the produced parts.
Implementation Method 1
a distributor that is movable with respect to the body, preferably in rotation about an axis, between a rest position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the first downstream discharge conduit, and at least a first supply position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the downstream work conduit
Implementation Method 2
The powder is generally conveyed in a stream of carrier gas, for example argon, to allow it to move. The gas flow rate generally does not vary during manufacturing.
Implementation Method 3
Additive construction or recharging by spraying metal powder or laser metal deposition (LMD) methods consist of melting metal powders with a laser or another melting method in order to generate a deposit with perfectly controlled dimensions
Data Source
AI summary
Disclosed is a switching system for a facility for 3D printing by spraying at least a first powder, including a body defining: at least one first upstream gas conduit configured to receive a gas; at least one first upstream powder conduit configured to receive the first powder; at least one first downstream discharge conduit for discharging the first powder; and a downstream work conduit configured in order to supply a nozzle designed for depositing at least the first powder. The system further includes a distributor that is movable with respect to the body, preferably in rotation about an axis, between a rest position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the first downstream discharge conduit, and at least a first supply position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the downstream work conduit.