3D Printer Build Module With Separate Controllers And Shutter Seals
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Solution Overview
Problem
Current 3D printing technologies face challenges in maintaining a controlled environment to prevent exposure of starting materials and unfinished objects to ambient atmospheric conditions, such as oxygen or humidity, which can affect the printing process and material integrity.
Innovation Solution
The implementation of a system where a build module and processing chamber are controlled by separate controllers, allowing for the creation of distinct atmospheres within a load lock area, and the use of a reversible shutter system to maintain a sealed environment during printing, enabling the use of granular materials like metals, ceramics, or carbon without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single controller is used for both build module and processing chamber, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to inability to maintain distinct atmospheric conditions
Solution Approach 1:
The control system is segmented into two independent controllers: a first controller for the build module and a second controller for the processing chamber. This segmentation allows each controller to independently manage its respective module's atmospheric conditions, enabling precise control of oxygen and humidity levels during printing without increasing overall system complexity.
Solution Approach 2:
A load lock chamber serves as an intermediary between the build module and processing chamber, allowing atmospheric conditions to be maintained independently in each zone. The load lock enables controlled transitions between different atmospheric environments without direct exposure, preserving manufacturing precision while managing system complexity.
2Ease of operation
If the build module is continuously exposed to ambient atmosphere, then ease of operation is improved, but material integrity deteriorates due to exposure to oxygen and humidity
Solution Approach 1:
The build module is equipped with an inert or controlled atmosphere system that prevents exposure to ambient oxygen and humidity. This controlled environment protects sensitive materials and unfinished printed objects from degradation while maintaining ease of operation through automated atmospheric management.
Solution Approach 2:
The controlled atmosphere system operates continuously throughout the printing process, maintaining protective conditions without interruption. This continuous protection ensures material integrity is preserved from start to finish of each printing operation.
3Ease of operation
If manual intervention is used for loading and unloading, then ease of operation is improved, but productivity deteriorates due to frequent interruptions in printing cycles
Solution Approach 1:
The system incorporates automated loading and unloading mechanisms that operate without manual intervention. The build module can be automatically loaded with raw materials and unloaded with finished products, allowing printing cycles to continue uninterrupted and maximizing productivity while maintaining operational simplicity through automation.
Solution Approach 2:
Materials are prepared and pre-positioned in the load lock chamber before the printing cycle begins. This preliminary preparation allows the printing process to proceed without interruption for material loading, thereby increasing productivity while keeping the interface simple and automated.
4Manufacturing precision
If heavy objects are printed with high translation precision, then manufacturing precision is improved, but device complexity increases due to requirements for high-accuracy positioning systems
Solution Approach 1:
The system replaces complex mechanical positioning mechanisms with field-based control methods, such as magnetic or electromagnetic positioning systems. This substitution achieves high translation accuracy for heavy objects during printing while reducing mechanical complexity and maintenance requirements.
Solution Approach 2:
The positioning system dynamically adjusts control parameters such as field strength, acceleration profiles, and damping characteristics to achieve high precision for heavy objects. By changing these parameters rather than increasing mechanical complexity, the system maintains manufacturing precision while keeping the device relatively simple.
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 allows for high-accuracy, high-stability, and high-repeatability 3D printing of heavy objects with reduced design constraints, enabling continuous operation with minimal interruptions and maintaining the integrity of the printed objects by controlling atmospheric conditions, thus enhancing the printing process efficiency and material properties.
Implementation Method 1
The build module may be reversibly sealable by a first shutter. The processing chamber may be reversibly sealable by a second shutter.
Implementation Method 2
engaging a build module with a processing chamber, wherein the build module comprises a platform, wherein the build module is controlled by a first controller and the processing chamber is controlled by a second controller
Implementation Method 3
The transforming can comprise melting or sintering the granular material. The transforming comprises can comprise melting the granular material.
Implementation Method 4
The transforming can comprise melting or sintering the granular material.
Implementation Method 5
a first layer of hardened material is formed (e.g., by welding powder), and thereafter successive layers of hardened material are added one by one, wherein each new layer of hardened material is added on a pre-formed layer of hardened material
Implementation Method 6
Some methods melt, sinter, or soften material to produce the layers that form the 3D object. Examples for 3D printing methods include selective laser melting (SLM), selective laser sintering (SLS), direct metal laser sintering (DMLS)
Data Source
AI summary
Provided herein are three-dimensional (3D) printing processes, apparatuses, software, devices, and systems for the production of at least one 3D object printed in a printing cycle, e.g., a 3D printer. The 3D printer describe herein may facilitate safe and accurate printing of 3D objects, e.g., when generated from reactive starting materials. The 3D printer (e.g., comprising a processing chamber, or a build module) may retain a requested (e.g., inert) atmosphere around the material bed and/or 3D object during the printing, e.g., at several 3D printing cycles. The 3D printer may comprise one or more build modules that may have a controller separate from the controller of that of the processing chamber. The 3D printer may comprises a platform that may be automatically constructed. The 3D printing may occur over a long time (e.g., many layers and/or one or more print cycles) without operator intervention and/or down time.