3D Printer Powder Hopper Transfer to Reduce Pluming
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Solution Overview
Problem
Powder-layer three-dimensional printers face challenges in creating uniform layers with fine powders, particularly those with average particle sizes less than 20 microns, and suffer from pluming issues due to fine powders being suspended in air currents, leading to non-uniform distribution and excess powder usage.
Innovation Solution
The use of ultrasonic vibrations to pelletize build powder as it is dispensed onto the build bed, combined with a perforated sheet screen and optional low-frequency vibration, enhances uniformity and reduces pluming, along with a discrete supply hopper and localized dust collection systems to manage powder distribution and containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fine powders with average particle sizes less than 20 microns are used to achieve fine feature resolution, then manufacturing precision is improved, but layer uniformity deteriorates and pluming occurs causing powder distribution problems
Solution Approach 1:
The patent applies ultrasonic vibration (mechanical vibration at high frequency) to the powder dispenser and/or build platform to prevent fine powder particles from clumping and to maintain uniform powder distribution during the layer deposition process, thereby resolving the layer uniformity problem while using fine powders for high precision printing
Solution Approach 2:
The patent implements an inert gas atmosphere (such as nitrogen or air with controlled humidity) in the build chamber to prevent fine powder particles from becoming suspended in air currents and causing pluming, thereby maintaining layer uniformity while enabling the use of fine powders for high resolution features
2Manufacturing precision
If fine powders are used to minimize layer thickness for fine feature resolution, then manufacturing precision is improved, but powder distribution uniformity deteriorates due to pluming in air currents
Solution Approach 1:
By maintaining an inert or controlled atmosphere in the build chamber, the patent prevents fine powder particles from becoming airborne and redistributing unevenly, thereby reducing the amount of excess powder needed to achieve uniform layer coverage and minimizing powder waste
Solution Approach 2:
The patent employs sensors to monitor powder distribution and layer formation in real-time, using feedback control to adjust dispensing parameters and compensate for any non-uniformity, thereby optimizing powder usage and reducing excess material consumption
3Device complexity
If conventional powder dispensing methods are used, then device complexity is kept simple, but layer uniformity deteriorates with fine powders
Solution Approach 1:
The patent incorporates ultrasonic vibration elements into the powder dispenser or build platform, adding a relatively simple mechanical component that significantly improves fine powder distribution and layer uniformity without substantially increasing overall system complexity
Solution Approach 2:
The patent implements an inert gas atmosphere system with controlled flow and pressure, which is a relatively straightforward modification to the build chamber that effectively prevents pluming and maintains layer uniformity while using fine powders
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 solution achieves improved layer uniformity, reduces excess powder usage, and minimizes pluming, ensuring consistent and efficient powder distribution across the build bed.
Implementation Method 1
a sheet screen (116) adapted to dispense the build powder (102) across the top of the build platform (100) or the powder bed (104) to form a powder layer; an ultrasonic transducer (30, 52) adapted to vibrate the sheet screen (28, 42) at frequencies at or above about 20,000 Hz
Implementation Method 2
a low frequency vibrator (32) adapted to assist the build powder (102) to flow from the hopper (26, 50) to the sheet screen (28, 42)
Data Source
AI summary
The present invention relates to powder-layer three-dimensional printers (2) having a discrete supply hopper (340) and a recoater (20). The discrete supply hopper (340) is configured to transfer a build powder to the recoater (20) in a manner that enhances the uniformity of build powder layers that are dispensed from the recoater (20). In some embodiments, at least one of the discrete supply hopper and the powder hopper of the recoater is adapted to selectively contact the other, seal against the other, and/or have one partially inserted inside the other so as to diminish or prevent powder pluming during the transfer of build powder from the discrete supply hopper to the recoater.