Print And Recoat Assembly for Build Material Reuse and Preheating
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Solution Overview
Problem
Conventional additive manufacturing systems face issues with stress application to underlying cured build material layers, leading to tearing or damage, and excess build material disposal increases costs, while inefficient energy application can cause defects.
Innovation Solution
A recoat assembly that returns excess build material to the supply for reuse, combined with an air distribution system for forced convection heat transfer using energy sources, ensuring efficient energy application without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If excess build material is deposited into a drain for reclamation or disposal, then the new layer of build material can be reduced to a desired thickness, but reclamation is time consuming and costly and disposal increases manufacturing costs
Solution Approach 1:
The recoat assembly recovers excess build material by redirecting it back to the build supply instead of disposing it. The housing directs excess material flow back to the supply receptacle, enabling reuse in subsequent layers, which reduces both time and cost while maintaining layer thickness precision
Solution Approach 2:
The system serves itself by automatically redirecting excess build material back to the supply without requiring external reclamation processes. The integrated housing and flow path design enables the system to reuse its own excess material, eliminating the need for separate reclamation operations
2Productivity
If the energy sources move over the build material and/or binder at high speed, then productivity is improved, but short residence time leads to insufficient energy being applied
Solution Approach 1:
The system changes the energy application parameter by using forced convection to preheat the build material before it reaches the high-speed energy source. This allows the energy source to maintain high speed while still achieving adequate total energy application, as the material is already warmed and requires less energy exposure time
Solution Approach 2:
The build material is preheated by forced convection before encountering the high-speed energy source. This preliminary heating action reduces the energy exposure time needed at the curing station, allowing high-speed operation while ensuring sufficient total energy application for proper curing
3Use of energy by moving object
If the amount of thermal energy emitted by the energy sources is increased, then the amount of energy applied to the build material and/or binder is increased, but build material and/or binder can burn or overheat
Solution Approach 1:
The system changes the temperature distribution parameter by preheating the build material uniformly through forced convection before it reaches the high-intensity energy source. This gradual heating approach allows the material to withstand higher energy application without burning, as the temperature increase is controlled and distributed
Solution Approach 2:
The build material undergoes preliminary uniform heating through forced convection before exposure to high-intensity energy. This preheating action prepares the material to receive higher energy doses without overheating, as the temperature gradient is managed and the material is already at an optimal starting temperature
4Use of energy by moving object
If the recoat assembly and/or print assembly moves slowly to allow longer energy application time, then sufficient energy is applied to the build material and/or binder, but the time to build an object increases
Solution Approach 1:
The system changes the temperature parameter by preheating the build material through forced convection, which reduces the residence time needed at the energy source. The material reaches optimal temperature faster, allowing high-speed processing while maintaining adequate total energy application for proper curing
Solution Approach 2:
The build material is preheated by forced convection before reaching the energy source, performing the preliminary heating action that would otherwise require long exposure time. This allows the assembly to move at high speed while still achieving sufficient total energy application, as the heating process begins before the material reaches the curing zone
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
Reduces manufacturing costs by reusing excess build material and enhances energy efficiency, preventing defects by ensuring adequate thermal energy application to build material and binder.
Implementation Method 1
an air distribution system that distributes heat generated by the one or more energy sources by forced convection
Implementation Method 2
The energy sources can be attached to the recoat assembly and/or the print assembly, and the energy sources may heat the build material and/or the binder
Data Source
AI summary
A method for forming an object includes moving an assembly including an energy source, heating an initial layer of build material (31i, 31s, 31, 3, 50) positioned in a build area via forced convection around the energy source of the assembly, and spreading build material (31) on the build area, thereby depositing a second layer of build material (31i, 31s, 31, 3, 50) over the initial layer of build material (31 i, 31s, 31, 3, 50).