Powder Recirculation Assembly for Low-Waste Additive Manufacturing
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Solution Overview
Problem
Conventional powder bed additive manufacturing technologies are inefficient due to excessive powder usage, weight issues, and complexity in large-scale systems, which increases costs and complicates part retrieval and chamber pressure management.
Innovation Solution
A powder recirculating additive manufacturing apparatus that dispenses powder in a continuous flow over a build platform, with a system to collect and reuse unused powder, utilizing a blower to recirculate it through a loop from a collection hopper back to the powder supply assembly, reducing the need for large powder beds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large powder bed is used to store unused powder, then the additive manufacturing process can continue, but the equipment weight increases, seals and chamber pressure problems are complicated, and part retrieval becomes difficult
Solution Approach 1:
The invention extracts the unused powder from the traditional powder bed system and separates it into a recirculating system. The powder dispenser moves away from the powder bed after dispensing, and unused powder is collected by a collection hopper and recirculated through a blower system, rather than being stored in a large stationary powder bed.
Solution Approach 2:
The system enables self-service by automatically recirculating unused powder through a closed-loop system. The blower automatically moves powder from the collection hopper back to the powder supply assembly, and the powder dispenser automatically replenishes itself, eliminating the need for manual powder bed management.
2Quantity of substance
If a large powder bed is used to store unused powder, then the additive manufacturing process can continue, but the equipment size and weight increase
Solution Approach 1:
The invention extracts the powder storage function from a large stationary powder bed and redistributes it dynamically. The powder is stored in a compact powder supply assembly that moves with the dispenser, and unused powder is collected in a small collection hopper, eliminating the need for a large fixed powder bed that would weigh down the elevator system.
Solution Approach 2:
The system transitions from a static large powder bed to a dynamic recirculating system. The powder supply assembly and collection hopper are much lighter than a large powder bed, and the blower system dynamically recirculates powder as needed, reducing the overall weight that the elevator system must support.
3Manufacturing precision
If conventional powder bed systems are used, then material can be built up layer-by-layer, but excessive powder is consumed and costs increase
Solution Approach 1:
The invention implements recovery of unused powder through a closed-loop recirculating system. The collection hopper collects powder that was not used in the previous layer, and the blower recirculates it back to the powder supply assembly for reuse in subsequent layers, dramatically reducing powder consumption compared to conventional systems where unused powder is discarded.
Solution Approach 2:
The recirculating system maintains continuous useful action by constantly recycling unused powder back into the build process. Instead of stopping to reload powder or discarding unused material, the system continuously recirculates powder, ensuring that nearly all powder is utilized and minimizing waste.
4Quantity of substance
If a large powder bed is used, then sufficient material is available for building, but the system becomes unmanageable in large bed systems
Solution Approach 1:
The invention segments the powder management system into discrete functional components: a compact powder supply assembly, a moving powder dispenser, and a collection hopper with recirculation. This segmentation replaces the monolithic large powder bed with manageable modular units that are easier to operate and maintain.
Solution Approach 2:
The continuous recirculation of powder ensures that material availability is maintained without requiring a large static powder bed. The blower continuously moves powder from the collection hopper back to the supply assembly, ensuring that sufficient material is always available for building while keeping the system compact and manageable.
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 minimizes powder usage, reduces equipment size and complexity, and enhances the flexibility of the build process by allowing for efficient reuse of powder, thereby saving time and money.
Implementation Method 1
a blower coupled to the collection hopper and configured to move powder collected in the collection hopper to the powder supply assembly for reuse
Implementation Method 2
The powder supply assembly includes a cyclone chamber with an annular side wall connected to a top wall; the powder feed tube enters the side wall all at an off-center position; and the air return tube enters the top wall at a central position
Data Source
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AI summary
An additive manufacturing apparatus (10) includes: a support surface (14) configured to support a build platform (16) thereon; a powder dispenser (20) disposed above the support surface (14), the powder dispenser (20) configured to dispense powder, and movable laterally over the support surface (14); a scraper (22) moveable over the build platform (16) and configured to scrape powder dispensed thereon by the powder dispenser (20), so as to provide a layer increment of powder above the build platform; and a directed energy source (26) configured to melt and fuse the layer increment of powder in predetermined pattern so as to form a part (42).