Powder Refill System for Additive Manufacturing

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Solution Overview

Problem

Conventional additive manufacturing machines face inefficiencies and downtime due to the need for frequent refilling of the powder dispenser, which requires significant movement of the build unit to a remote refill zone, disrupting gantry movement and increasing operational costs.

Innovation Solution

A powder refill system positioned below the gantry, utilizing a conveyor to transport additive powder from a supply source to the dispenser, allowing continuous supply and minimizing the need for the build unit to move during refilling, thus maintaining gantry mobility and reducing downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the powder dispenser is refilled using conventional methods with the build unit moving to a remote refill zone, then the powder can be replenished, but the gantry movement is disrupted and significant downtime occurs

Engineering Contradiction:

Improvepowder supplyVSAvoidrefill downtime

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

Instead of moving the build unit to a remote refill zone, the invention inverts the approach by bringing the powder refill system to the build unit. The powder dispenser is refilled in place at the build position, eliminating the need for lengthy gantry movements to remote zones and significantly reducing refill downtime.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The build unit is equipped with an integrated powder dispenser that can be refilled in place, allowing the system to service itself without requiring movement to external refill stations. This self-service capability maintains continuous operation and eliminates interruptions in the additive manufacturing process.

Inventive Principle:

Principle #25Self-service

2Quantity of substance

If the build unit moves frequently to refill zones, then the powder dispenser can be refilled, but productivity decreases due to operational disruptions

Engineering Contradiction:

Improvepowder supplyVSAvoidmanufacturing output

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The invention enables continuous additive manufacturing operation by allowing the powder dispenser to be refilled in place without interrupting the build process. The build unit remains stationary at the build position while powder is replenished, maintaining continuous useful action and maximizing manufacturing productivity.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If the powder dispenser is refilled by positioning it above the gantry, then powder can be deposited by gravity, but the gantry movement is obstructed and efficiency is reduced

Engineering Contradiction:

Improvepowder depositionVSAvoidrefill efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention extracts the powder deposition function from the gantry system and integrates it into the build unit. By incorporating a powder dispenser directly on the build unit, the system eliminates the need for overhead powder deposition mechanisms that would obstruct gantry movement, thereby improving refill efficiency and overall productivity.

Inventive Principle:

Principle #2Taking out (Extraction)

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 solution enables faster and more cost-effective additive manufacturing by reducing downtime and movement constraints, allowing for continuous operation and improved powder management within the manufacturing process.

Implementation Method 1

the powder supply system comprises a conveyor that transports the additive powder to the powder dispenser

Methodology Applied

Scientific EffectConveyor transport:

Implementation Method 2

an energy source for selectively directing energy toward the layer of the additive powder to fuse portions of the layer of the additive powder

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

direct metal laser melting (DMLM), an apparatus builds objects in a layer-by-layer manner by sintering or melting a powder material using an energy beam

Methodology Applied

Scientific EffectSelective laser melting:

Implementation Method 4

The hopper is filled with additive powder which is dispensed layer-by-layer during the AM process

Methodology Applied

Scientific EffectGravity flow: Gravitation

Data Source

PatentEP3706940B1Powder refill system for an additive manufacturing machine

Publication Date: 2024.05.29 GENERAL ELECTRIC CO

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AI summary

An additive manufacturing machine (910) includes a build platform (908) extending within a horizontal plane (H) and a gantry (930) positioned above the build platform (908) and defining a build area (932). A build unit (920) includes a powder dispenser (906) for discharging a layer of additive powder (902) and an energy source (922) for selectively directing energy toward the layer of additive powder (902) to fuse portions of the layer of additive powder (902). The gantry (930) movably supports the build unit (920) within the build area and a powder supply system (900) is positioned below the gantry (930) and extends between a powder supply source (940) and the powder dispenser (906).