Post-Build Powder Removal System for Additive Manufacturing

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Solution Overview

Problem

The existing powder bed fusion additive manufacturing process is labor-intensive and time-consuming for removing non-fused powder from the build platform, particularly for delicate parts, and poses hazards due to loose powder.

Innovation Solution

A post-build powder removal system with a work bed and platform wall featuring selectively openable powder evacuation ports, a sealing system, and components like a vibration motor, perforated screen, and pressurized air source to efficiently remove loose powder without damaging the parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual sweeping and vacuuming are used to remove non-fused powder, then the powder removal purpose is achieved, but the process becomes labor intensive and time consuming

Engineering Contradiction:

Improvepowder removal efficiencyVSAvoidtime for powder removal

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical operations (sweeping and vacuuming) with an automated vibration-based ejection system. The build platform receives vibrations that cause non-fused powder to be ejected through evacuation ports, eliminating the need for manual intervention and significantly improving powder removal efficiency while reducing time consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the build platform to automatically eject non-fused powder through vibration-induced self-ejection. The platform's own structural components (evacuation ports) work in conjunction with the vibration source to autonomously remove powder without requiring external manual operations or additional equipment.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual sweeping is used to remove powder, then powder removal is achieved, but care must be used to avoid damaging delicate 3-D parts

Engineering Contradiction:

Improvepowder removal efficiencyVSAvoidpart integrity during powder removal

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces contact-based manual sweeping with a non-contact vibration-based ejection system. The vibrations cause non-fused powder to be ejected through evacuation ports without requiring physical contact with the 3-D part, thereby eliminating the risk of damaging delicate features while maintaining efficient powder removal.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system applies vibration energy locally to the build platform and non-fused powder regions, causing selective ejection of loose powder through evacuation ports while leaving the fused 3-D part undisturbed. This localized action ensures efficient powder removal without compromising part integrity.

Inventive Principle:

Principle #3Local quality

3Productivity

If manual vacuuming is used to remove powder, then powder removal is achieved, but the process becomes labor intensive

Engineering Contradiction:

Improvepowder removal efficiencyVSAvoidautomation level of powder removal

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The patent replaces manual vacuuming operations with an automated vibration-based ejection system. The build platform is equipped with vibration sources and evacuation ports that work together to automatically eject non-fused powder, eliminating the need for manual vacuuming and significantly increasing automation level while improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

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 reduces labor and time required for powder removal, minimizes damage to the parts, and mitigates hazards by using vibration and targeted gas flows to evacuate loose powder effectively.

Implementation Method 1

The vibration motor is configured to selectively vibrate the build platform to facilitate removal of the non-fused powder material

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 2

a pressurized air source configured to selectively blow and remove loose powder material from the build platform

Methodology Applied

Scientific EffectGas flow: Convection

Data Source

PatentUS11534972B2Post-build quick powder removal system for powder bed fusion additive manufacturing

Publication Date: 2022.12.27 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A post-build powder removal system includes a work bed, a platform wall having at least one powder evacuation port, and an evacuation port sealing system operable for selectively closing and opening the powder evacuation port. The platform wall cooperates with the work bed to define a powder chamber. The evacuation port sealing system includes an external sleeve slidingly fitted onto the exterior surface of the platform wall such that the external sleeve is slideable in a first direction closing the at least one powder evacuation port and slideable in an opposite second direction opening the at least one powder evacuation port.