Powder Injector Path Control for Adaptive Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing processes face inefficiencies in powder management, including excessive powder usage, difficulty in adapting to part geometry, complex powder circuits, and lengthy batch changes, which increase manufacturing costs and time.
Innovation Solution
A process utilizing a movable point injector that regulates powder distribution on the work surface based on the part's geometry and dimensions, allowing for precise control of powder quantity and reduced excess powder, integrated with a cleaning mechanism to streamline batch changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed spreading device (roller or scraper) is used to distribute powder, then the powder can be spread uniformly on the work surface, but the amount of excess powder is large and cannot be adapted to different part geometries
Solution Approach 1:
The patent replaces the fixed spreading device with a movable point injector that can dynamically adjust its position and powder distribution according to the part geometry. The injector moves along the work surface in both longitudinal and transverse directions, allowing the powder distribution area to be dynamically adapted to match the actual part dimensions, thereby reducing excess powder while maintaining uniform distribution where needed.
Solution Approach 2:
The point injector delivers powder locally to specific areas of the work surface based on the part geometry requirements. Instead of uniformly spreading powder across the entire work surface, the injector concentrates powder only where needed for the current layer, creating local quality in powder distribution that matches the part's actual shape and reduces overall powder consumption.
2Adaptability or versatility
If the spreading device length is increased to cover larger part dimensions, then larger parts can be manufactured, but the amount of excess powder increases and the device complexity increases
Solution Approach 1:
The point injector system provides dynamic adaptability to different part sizes through programmed movement along the work surface. The injector can traverse the entire work surface area as needed, eliminating the need for fixed spreading devices of various lengths. This dynamic approach allows the same injector to adapt to any part size without increasing excess powder, as powder is delivered only to the areas currently being processed.
3Manufacturing precision
If a complex powder circuit with multiple sub-assemblies (reservoir, injector, gutter) is used, then powder distribution can be controlled, but the batch change time increases and cleaning time increases
Solution Approach 1:
The patent extracts the powder distribution function from the complex multi-component system (reservoir-injector-gutter) and integrates it directly into a simplified injector unit. By combining the powder delivery and distribution functions into a single injector that moves along the work surface, the system eliminates the need for separate gutters and complex powder circuits, thereby reducing batch change time and cleaning requirements while maintaining precise powder quantity control.
4Reliability
If excess powder is provided to ensure complete coverage of the target surface, then the powder coverage is adequate, but the manufacturing cost increases and the powder management complexity increases
Solution Approach 1:
The point injector ensures reliable powder coverage by delivering powder locally to each area of the work surface as it moves along the programmed path. This localized delivery ensures that each region receives the exact amount of powder needed for complete coverage, eliminating the need for excessive powder provision while maintaining coverage reliability. The system monitors and controls powder delivery at each location, ensuring adequate coverage without waste.
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 approach reduces excess powder usage, minimizes manufacturing time, facilitates precise powder metering, and decreases cleaning time and recycling costs by optimizing powder distribution and management.
Implementation Method 1
an additive manufacturing process comprising a powder distribution step performed by an injector (6) which distributes powder directly on the work surface (2)
Implementation Method 2
a melting and solidification step. For this purpose, a supply of energy, for example by a laser beam, makes it possible to draw in the layer of powder a solid corresponding to the edge of the part to be manufactured
Implementation Method 3
a spreading device, which is typically a roller or a scraper, moving transversely to the line of powder and thus ensuring the spreading of the powder
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a process for the additive manufacturing of a workpiece (P) in a machine (1) comprising: - a working surface (2); - a device (5) for spreading the powder layer in at least one longitudinal horizontal direction; - at least one powder injector (6) for dispensing powder on the working surface (2), said injector (6) being movable relative to the working surface (2) in at least one transverse horizontal direction; - a system for adjusting the amount of powder dispensed by the injector (6); the process involves the following steps: - moving the injector (6) along a path having at least one component extending parallel to the transverse horizontal direction; - adjusting the amount of powder dispensed by the injector (6) at every point along the path of the injector (6).