Additive Manufacturing Powder Layer Forming Mechanism
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Solution Overview
Problem
In additive manufacturing using the powder depositing-and-melting method, projecting solidified portions can interfere with the powder-layer forming mechanism, leading to apparatus stoppages and inaccuracies in product shape, especially during single-product or multiple-products manufacturing, as they can cause the mechanism to catch or result in insufficient powder supply.
Innovation Solution
The method involves a powder-layer forming step using a high-rigidity and a low-rigidity thickness-determining portion, where the high-rigidity portion forms the powder layer until reaching a projecting portion, then retracts and the low-rigidity portion continues layer formation around it, ensuring consistent thickness and preventing apparatus stoppages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the powder-layer forming mechanism retracts upward while moving horizontally to avoid projecting portions, then apparatus stoppages are prevented, but the material powder supply becomes insufficient and powder layer thickness becomes non-uniform
Solution Approach 1:
The powder-layer forming mechanism is divided into multiple independent blades (first blade, second blade, third blade) that can operate independently. When a projecting portion is detected, only the first blade retracts while the second and third blades continue to supply powder and form the layer, ensuring continuous and uniform powder distribution without apparatus stoppage.
Solution Approach 2:
The system dynamically adjusts the position of the first blade based on real-time detection of projecting portions. The control unit commands the first blade to retract vertically when a projecting portion is detected, and to return to its original position afterward, allowing adaptive response to irregularities while maintaining continuous manufacturing.
2Strength
If the powder-layer forming mechanism contacts projecting portions, then apparatus stoppages occur, but using a high-rigidity thickness-determining portion prevents deformation while a low-rigidity portion allows flexibility
Solution Approach 1:
Different blades are assigned different rigidity characteristics based on their specific functions. The first blade (detection and avoidance) is designed with higher rigidity for precise positioning, while the second and third blades (powder supply and layer formation) are designed with appropriate rigidity to maintain contact and ensure uniform powder distribution, allowing each component to optimize its performance for its specific role.
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 allows continuous additive manufacturing with high accuracy, even when projecting portions are unintentionally formed, by avoiding interference and maintaining consistent powder layer thickness, thus enhancing productivity and product quality.
Implementation Method 1
a process to solidify a portion of the powder layer by selectively heating the portion by irradiating the portion with a laser beam
Implementation Method 2
selectively heating the portion by irradiating the portion with a laser beam
Implementation Method 3
for melting or sintering the portion
Implementation Method 4
and by cooling the portion
Data Source
AI summary
An additive manufacturing apparatus includes a base, a layer forming portion configured to form a powder layer having a predetermined thickness by moving in a space above the base, an irradiation portion configured to irradiate the powder layer with an energy beam, a detection portion configured to detect a projecting portion formed on a solidified portion and a position of the projecting portion, and a control unit. The solidified portion is formed by irradiating the powder layer with the energy beam from the irradiation portion. A height of the projecting portion is larger than the predetermined thickness. The layer forming portion includes a high-rigidity thickness-determining portion and a low-rigidity thickness-determining portion. The control unit is configured to control operation of the high-rigidity thickness-determining portion and the low-rigidity thickness-determining portion, depending on a detection result by the detection portion.