Powder Metering in 3D Printing for Selective Layer Recoating
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Solution Overview
Problem
Existing generative layer-by-layer manufacturing methods for three-dimensional objects face inefficiencies in powder usage, leading to prolonged manufacturing times, increased wear of handling systems, and limited object height due to excessive powder consumption and the need for frequent refills, with the additional complication of unpacking processes.
Innovation Solution
A method and device that optimizes powder metering by dynamically adjusting the amount applied based on the object's geometry, using a metering device with adjustable plungers or integrated storage chambers to ensure precise powder application only where needed, minimizing waste and simplifying the unpacking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If powder application is carried out across the total area of the building chamber, then the entire area is coated, but manufacturing time is prolonged and powder consumption increases
Solution Approach 1:
The building chamber area is segmented into a building cell (first area) and a non-building area (second area). The recoater is configured to apply powder only to the building cell where the three-dimensional object is being manufactured, rather than coating the entire building chamber. This segmentation allows selective powder application to the relevant manufacturing zone, reducing unnecessary powder consumption and handling time.
Solution Approach 2:
The recoater implements local quality by differentiating powder application between two distinct areas: the building cell where powder is applied and the non-building area where powder is not applied. This localized approach ensures that powder is only consumed where it is needed for manufacturing, eliminating waste in surrounding areas and improving overall process efficiency.
2Loss of substance
If confining walls are built within the building chamber to reduce powder usage, then powder consumption decreases, but the unpacking procedure becomes complicated
Solution Approach 1:
The invention extracts the powder application function from the entire building chamber and confines it only to the building cell area. By using a recoater that selectively applies powder only where needed, the system eliminates the need for confining walls made of solidified building material. This approach reduces powder consumption while maintaining simple unpacking procedures, as no additional confining structures are created.
3Quantity of substance
If large amounts of powder are used, then sufficient material is available for manufacturing, but handling system wear increases and refill frequency increases
Solution Approach 1:
The recoater is configured with dynamic powder application capabilities, adjusting the application area to match the building cell dimensions. This dynamic approach ensures that powder is applied only to the necessary area, optimizing the balance between powder availability and handling system wear. The system adapts powder distribution to the actual manufacturing needs, reducing excessive powder usage and associated handling wear.
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
Reduces powder consumption, minimizes system wear, and streamlines the manufacturing process by optimizing powder usage and simplifying the unpacking of completed objects, thereby enhancing efficiency and reducing operational costs.
Implementation Method 1
a building material layer is applied on a height-adjustable support and selectively solidified in a building chamber
Implementation Method 2
DE 10 2011 121 568 A1 describes a generative layer manufacturing method in which a metal material in powder form is selectively solidified by means of electromagnetic radiation or electron beam radiation
Data Source
AI summary
A method of manufacturing an object in a build area by successive layer-by-layer solidification of a building material in powder form.The method includes applying a layer of the building material in powder form having a predetermined thickness onto a layer of the building material already previously applied which has been solidified in a region corresponding to a cross section of the object A recoater is moved in a direction across the layer already previously applied, and the building material is solidified in a shape corresponding to a cross section of the object.Prior to the application of a layer, for a solidified region having a thickness d1 in the layer applied before, the maximum of the product of the extension of this region in movement direction of the recoater and the thickness d1 is determined and during the application of the layer, at least an additional powder amount proportional to the value of the maximum is additionally provided.