3D Printing Powder Layer Density via Dynamic Flattening

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Solution Overview

Problem

Existing three-dimensional fabrication devices face challenges in achieving high powder density and accurate fabrication due to insufficient powder layer formation, leading to deteriorated fabrication accuracy and quality.

Innovation Solution

The device forms an excessively thick powder layer and removes powder from the top surface multiple times, with the amount of powder removed decreasing in subsequent steps, and uses a flattening roller to bind the powder, optimizing the powder layer thickness and density by adjusting the roller's speed and direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the flattening roller removes powder multiple times with constant thickness, then the powder layer thickness is controlled, but the powder density is insufficient

Engineering Contradiction:

Improvepowder layer thickness controlVSAvoidpowder density

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent applies dynamics by varying the removal thickness dynamically across multiple flattening operations. The removal thickness transitions from larger values in earlier operations to smaller values in later operations, creating a progressive refinement effect that increases powder density while maintaining thickness control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the parameter of removal thickness across multiple flattening operations. By adjusting the removal thickness parameter from larger to smaller values in successive operations, the system optimizes both thickness control and powder density, resolving the contradiction between precision and material quantity.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the flattening roller moves slowly to form powder layer, then the powder layer is formed thoroughly, but the productivity is reduced

Engineering Contradiction:

Improvepowder layer formation qualityVSAvoidfabrication speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent segments the powder layer formation process into multiple flattening operations with different removal thicknesses. This segmentation allows the system to achieve thorough powder layer formation through progressive refinement while maintaining higher overall productivity by optimizing each individual operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent maintains continuity of useful action by performing multiple flattening operations in sequence without interrupting the overall fabrication process. Each operation contributes to the final powder layer quality, and the cumulative effect achieves thorough formation while maintaining production flow.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If the flattening roller removes large amount of powder each time, then the process is faster, but the fabrication accuracy deteriorates

Engineering Contradiction:

Improvepowder removal efficiencyVSAvoidfabrication accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by transitioning from large removal thicknesses in early operations to small removal thicknesses in later operations. This dynamic adjustment allows efficient powder removal initially while achieving high fabrication accuracy in the final operations, resolving the contradiction between speed and precision.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent performs preliminary powder removal with larger thicknesses in early operations to quickly reduce excess material, then performs final precision removal with smaller thicknesses. This preliminary action approach maintains productivity while ensuring final fabrication accuracy.

Inventive Principle:

Principle #10Preliminary action

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 enhances powder density and fabrication accuracy by ensuring a uniform powder layer with increased density, improving the quality of the three-dimensional fabrication objects.

Implementation Method 1

a flattening member to place powder in the fabrication part to form an excessively thick powder layer and remove the powder on the top surface side of the excessively thick powder layer multiple times

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

a fabrication unit to bind the powder in the powder layer to form a laminar fabrication object

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11179777B2Device for fabricating three-dimensional fabrication object and method of manufacturing three-dimensional fabrication object

Publication Date: 2021.11.23 RICOH CO LTD

AI summary

A device for fabricating a three-dimensional fabrication object includes a fabrication part, a flattening member to place powder in the fabrication part to form an excessively thick powder layer and remove the powder on the top surface side of the excessively thick powder layer multiple times to obtain a powder layer while moving in a direction orthogonal to a lamination direction of the powder layer, and a fabrication unit to bind the powder in the powder layer to form a laminar fabrication object, (wherein the laminar fabrication object is formed repeatedly to fabricate the three-dimensional fabrication object), wherein the amount of a layer thickness of the powder removed for the last time is less than that for any other time.