Additive Manufacturing Powder Tracking for Consistent Build Quality
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Solution Overview
Problem
Existing additive manufacturing methods for three-dimensional objects face challenges in maintaining the quality of build materials due to repeated use and post-processing, which can affect mechanical properties and particle size distribution, leading to inconsistent object quality.
Innovation Solution
A method to determine the number of manufacturing and sieving processes a build material has undergone, allowing for the addition of fresh material to compensate for degradation, and using a determination unit to store and update process information for each build material container, ensuring proper post-processing and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If build material is reused after manufacturing processes, then productivity is improved through material recycling, but manufacturing precision deteriorates due to particle size distribution changes and quality degradation
Solution Approach 1:
The patent applies parameter changes by monitoring the number of manufacturing processes a build material has undergone and using this information to determine when to add fresh material. The system changes the composition parameter of the build material container by adding fresh material (0 times used) to mixed material (multiple times used), thereby restoring the particle size distribution and quality characteristics without completely discarding the reused material.
2Productivity
If build material undergoes multiple manufacturing processes, then productivity is improved through continuous operation, but reliability deteriorates due to quality degradation and particle size distribution changes
Solution Approach 1:
The patent implements feedback by using a determination unit that tracks the number of manufacturing processes each build material has undergone. This information is stored and updated after each process, providing continuous feedback to the control unit. Based on this feedback, the system automatically determines when to add fresh material to maintain quality standards, ensuring reliable continuous operation.
3Manufacturing precision
If post-processing is performed on non-consolidated build material, then manufacturing precision is improved through particle separation, but device complexity increases due to additional processing equipment
Solution Approach 1:
The patent applies self-service by integrating the tracking and management functions directly into the existing additive manufacturing apparatus. The determination unit and control unit are built-in components that automatically monitor build material usage and make decisions about when to add fresh material, eliminating the need for external complex post-processing equipment for quality management.
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 ensures that build materials are properly post-processed and maintained at optimal quality, improving the consistency and quality of manufactured objects by tracking and managing the usage and quality of build materials effectively.
Implementation Method 1
a information storage is provided in which the number of build processes and/or the number of sieving processes is stored
Implementation Method 2
selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source, e.g. a laser beam or an electron beam
Implementation Method 3
selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy source, e.g. a laser beam or an electron beam
Data Source
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AI summary
Method for operating at least one apparatus (1) for additively manufacturing of three-dimensional objects (2) by means of successive layerwise selective irradiation and consolidation of layers of a build material (3, 14) which can be consolidated by means of an energy source, which apparatus (1) comprises at least one build material container (4, 8) adapted to receive build material (3, 14), characterized in that the number of build processes at least one part of the build material (3, 14) received in the at least one build material container (4, 8) has been used in is determined.