Powder Reclamation System for Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing machines face challenges in efficiently recycling and sieving metal powders due to the size and weight of printed objects, requiring an effective powder reclamation system to recover and filter unused powders for recirculation.

Innovation Solution

A powder reclamation system that includes a filter housing with a broad frequency filter assembly, separating powders larger than a predetermined threshold from those smaller, and recirculating the filtered reclaimed powder with a controlled mixture of virgin powder back to the processing device, utilizing a network of passageways and a controller for efficient powder management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If powder is removed and collected after each machine cycle, then powder recycling is achieved, but the process becomes difficult due to size and weight of printed objects

Engineering Contradiction:

Improvepowder recycling efficiencyVSAvoiddifficulty of powder removal

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system separates powder collection into two streams: unused powder is collected and reused, while used powder is discarded. The recirculation system segments the powder flow path to enable efficient collection without moving heavy printed objects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A recirculation pump acts as an intermediary device to transfer powder between the build chamber and storage containers, eliminating the need to physically move large printed objects for powder collection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If reclaimed powder is recirculated, then material utilization is improved, but powder size distribution may deteriorate

Engineering Contradiction:

Improvepowder utilizationVSAvoidpowder size distribution

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The system performs preliminary sifting of reclaimed powder before recirculation, separating powder into different size fractions. This preliminary action ensures that only appropriately sized powder is recirculated, maintaining size distribution requirements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the size parameter of reclaimed powder through mechanical sifting and classification processes, separating powder into different size ranges to maintain optimal size distribution for additive manufacturing.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If a filter system is added to separate powder sizes, then powder quality is improved, but device complexity increases

Engineering Contradiction:

Improvepowder size separationVSAvoidsystem structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The sifting system is designed to automatically separate and classify powder without requiring external intervention. The system self-regulates powder flow and size separation, reducing operational complexity despite added filtration components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The recirculation system performs multiple functions: it collects unused powder, sifts reclaimed powder, separates size fractions, and recirculates appropriate powder back to the build chamber. This multi-functionality consolidates what could be multiple separate systems into one integrated unit.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system effectively recovers, filters, and recirculates metal powders, maintaining a desired size distribution and mix, enhancing the efficiency of additive manufacturing processes by reducing waste and extending powder usage.

Implementation Method 1

separating powders larger than a predetermined threshold from those smaller, and recirculating the filtered reclaimed powder

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11794256B2Powder reclamation system and operating method

Publication Date: 2023.10.24 GENERAL ELECTRIC CO

AI summary

A powder reclamation system for reclaiming a metal powder from a metal powder processing device is provided. The powder reclamation system includes a filter housing defining an inlet and an outlet; a filtered reclaimed powder hopper in communication with the outlet of the filter housing for receiving a filtered reclaimed powder; a powder recirculation passageway configured for providing a flow of powder to a metal powder processing device, the powder recirculation passageway in flow communication with the filtered reclaimed powder hopper; a virgin powder hopper containing a virgin powder also in communication with the powder recirculation passageway; and a controller operable with the powder reclamation system for providing a mixture of the filtered reclaimed powder and the virgin powder through the powder recirculation passageway.