Powder Reduction Apparatus Using Segmented Build Inserts
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Solution Overview
Problem
Conventional additive manufacturing using powder-based build materials requires large quantities of powder, leading to high overhead costs, contamination risks, and health hazards due to excess powder, as well as inefficiencies in powder usage and processing.
Innovation Solution
The use of a build insert that divides the powder bed into smaller, separate build areas, allowing powder to be layered only where needed, reducing the amount of powder required by up to 50% and enabling more efficient use of powder-based build materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire build platform is completely covered in powder to ensure sufficient material for building parts, then the reliability of the manufacturing process is improved, but the quantity of powder required increases significantly
Solution Approach 1:
The build platform is divided into multiple build areas using build inserts, allowing powder to be confined to specific regions where parts will be manufactured. This segmentation enables reduction of total powder quantity while maintaining sufficient powder coverage in each active build area, thus resolving the contradiction between reliability and powder quantity.
2Adaptability or versatility
If large quantities of powder are used to cover the build platform, then the manufacturing process can accommodate various part configurations, but the loss of substance increases due to contamination and waste
Solution Approach 1:
By segmenting the build platform into multiple isolated build areas using build inserts, the system maintains adaptability for different part configurations within each area while reducing overall powder usage. Excess powder in inactive areas is eliminated, directly reducing material loss and waste.
Solution Approach 2:
The build inserts are extracted from the powder bed after manufacturing, allowing the contained powder to be removed and reused. This extraction process enables recovery of powder that would otherwise be contaminated and discarded, reducing substance loss.
3Quantity of substance
If the build insert is lowered into the powder bed during the additive manufacturing process, then the powder bed is divided into separate build areas reducing powder usage, but the device complexity increases
Solution Approach 1:
The build insert is designed with movable components that can be lowered into and raised from the powder bed dynamically during the manufacturing process. This dynamic adjustment enables the system to transition between different build area configurations, reducing powder usage while managing complexity through controlled motion rather than fixed complex structures.
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 decreases powder usage, minimizes health risks, reduces manufacturing costs, and allows for one-piece flow and ergonomic benefits, while eliminating the need for additional equipment like EDM wire cutting.
Implementation Method 1
uses electromagnetic radiation such as a laser beam, to melt or sinter a powdered material, creating a solid three-dimensional object
Implementation Method 2
a filament that emits electrons when a current flows through it
Implementation Method 3
spread evenly over a powder bed 142 using a recoater arm 146 travelling in direction 164 to maintain the powder at a build level 148
Implementation Method 4
The build platform 144 is lowered and another layer of powder is spread over the powder bed and object being built
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The present disclosure relates generally to methods and apparatuses for additive manufacturing using reduced amounts of powder-based built materials. Such methods and apparatuses mitigate several drawbacks of conventional power-based methods, including high powder overhead, increased costs, ergonomic strain on machine operators, health risks, and risk of short powder feeds.