Powder And Gas Dispenser Layout for Faster Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing, existing systems face challenges in increasing throughput and maintaining the quality of the process due to temperature fluctuations and the need for efficient cooling of sintered or melted layers before adding subsequent layers.
Innovation Solution
An additive manufacturing system that includes a coolant fluid dispenser to cool the outermost layer of feed material after it has been fused, allowing for simultaneous cooling across the width of the platen and movement in conjunction with the energy source, thereby expediting the processing of the next layer and reducing temperature fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional additive manufacturing systems process layers sequentially without simultaneous cooling, then the system structure remains simple, but the throughput is reduced and temperature fluctuations affect quality
Solution Approach 1:
The patent combines the coolant fluid dispenser with the energy source onto a common support structure, allowing both components to move together as a single unit. This merging enables simultaneous heating and cooling operations without requiring separate mounting systems, thereby increasing throughput while limiting the increase in overall system complexity.
Solution Approach 2:
The coolant fluid dispenser is positioned to deliver coolant to the outermost layer before the energy source completes its processing of that layer. This preliminary cooling action prepares the layer for the next operational cycle in advance, reducing idle time and improving throughput without requiring complex sequential coordination.
2Manufacturing precision
If the energy source processes the outermost layer completely before cooling, then the system operation is simple, but temperature fluctuations reduce manufacturing precision
Solution Approach 1:
The coolant fluid dispenser is configured to deliver coolant fluid to specific locations on the outermost layer where thermal management is needed, rather than uniformly cooling the entire build plate. This localized cooling approach improves manufacturing precision by controlling temperature fluctuations in critical areas without requiring a complex system-wide cooling infrastructure.
Solution Approach 2:
The coolant fluid acts as an intermediary substance that absorbs excess heat from the outermost layer during and after energy source processing. This mediator enables precise temperature control to maintain manufacturing quality without requiring direct mechanical intervention or complex active cooling systems.
3Productivity
If rapid cooling is applied to expediting next layer processing, then throughput increases, but thermal stress may affect material properties
Solution Approach 1:
The coolant fluid dispenser operates in periodic cycles, delivering coolant fluid at controlled intervals during and after energy source processing. This periodic cooling action enables rapid heat removal to maintain processing speed while avoiding continuous aggressive cooling that would induce excessive thermal stress and compromise material properties.
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
The system enhances throughput and improves the quality of the additive manufacturing process by ensuring rapid cooling of sintered or melted layers, preventing accidental fusion or melting of subsequent layers and reducing thermal stress, thus improving material properties.
Implementation Method 1
Sintering is a process of fusing small grains, e.g., powders, to create objects. Sintering usually involves heating a powder. When a powdered material is heated to a sufficient temperature in a sintering process, the atoms in the powder particles diffuse across the boundaries of the particles, fusing the particles together to form a solid piece.
Implementation Method 2
Some methods melt or soften material to produce layers, e.g., selective laser melting (SLM) or direct metal laser sintering (DMLS). Selective laser melting (SLM) is used for crystalline and semi-crystalline materials such as nylon and metals, which have a discrete melting/freezing temperature and undergo melting during the SLM process.
Implementation Method 3
a coolant fluid dispenser to deliver a coolant fluid onto the outermost layer of feed material after at least a portion of the outermost layer has been fused
Data Source
AI summary
An additive manufacturing system includes a platen having a top surface, a support structure, a powder dispenser coupled to the support structure and positioned above the platen and configured to deliver a powder in a linear region that extends along a first axis, a gas dispenser coupled to the support structure in a fixed position relative to the powder dispenser and having an outlet to deliver a gas across the outermost layer of feed material, an energy source configured to selectively fused the layer of powder, and an actuator coupled to the support to move the support with the powder dispenser and the gas dispenser together along a second axis perpendicular to the first axis and parallel to the top surface such that the linear region and the outlet sweep along the second axis to deposit the powder in a swath over the platen and deliver the gas.