3D Printer Controller for Progressive Alloy Composition
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Solution Overview
Problem
Existing methods for producing metallic articles, such as casting and powder spraying, struggle to create parts with varying characteristics without adjusting wall thickness or applying heat treatment, which affects the entire article or only its outer skin.
Innovation Solution
A 3D printer system with multiple feeders for metallic powders and a computerized controller that adjusts the relative disposition and proportions of the powders to create articles with specific characteristics, such as strength, conductivity, or corrosion resistance, by varying the materials and their proportions across different parts of the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If homogeneous metallic material is used in casting or powder spraying, then the manufacturing process is simple, but all parts of the article have uniform properties requiring wall thickness adjustment to achieve varying strength
Solution Approach 1:
The material delivery system is segmented into multiple independent feeders (first feeder, second feeder, etc.), each capable of delivering different metallic powders. This segmentation allows the system to provide varying material compositions to different regions of the article without requiring a completely complex redesign, as each feeder operates independently but can be coordinated by a computerized controller.
Solution Approach 2:
The patent implements local quality by enabling different portions of the article to receive different metallic powders or different proportions of powder mixtures. The computerized controller adjusts the material composition delivered to specific locations based on the desired properties of each region, such as varying strength, conductivity, or corrosion resistance requirements for different parts of the same article.
2Manufacturing precision
If multiple metallic powders are delivered to create varying article characteristics, then regional property control is improved, but the device complexity increases
Solution Approach 1:
The computerized controller implements feedback control by monitoring the delivery of multiple metallic powders and adjusting the feeders accordingly. The controller receives information about the desired material composition for each region and continuously adjusts the feeders to achieve the precise proportions required, ensuring accurate material composition control despite the complexity of coordinating multiple feeders.
Solution Approach 2:
The computerized controller acts as an intermediary between the multiple feeders and the final article production. It coordinates the complex interactions between feeders, manages the timing and proportions of material delivery, and translates design requirements into specific feeder commands, thereby managing device complexity while maintaining manufacturing precision.
3Strength
If post-forming heat treatment is applied to adjust powder sprayed article properties, then material characteristics can be modified, but the entire volume or only outer skin is affected uniformly
Solution Approach 1:
The patent applies preliminary action by incorporating the desired material composition directly into the article during the manufacturing process itself. Different metallic powders or powder proportions are delivered to different regions before the article is completed, eliminating the need for subsequent heat treatment to achieve regional property variations. This preliminary differentiation of material composition allows selective property control without affecting the entire article uniformly.
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
Enables the creation of articles with tailored properties across different regions, allowing for precise control of characteristics like strength, conductivity, and corrosion resistance without altering wall thickness, offering a versatile method for producing complex metal objects with varying properties.
Implementation Method 1
the print materials are each conveyed in a gas (eg air) stream
Data Source
AI summary
The invention relates to a 3D printer. The 3D printer includes a first feeder containing a metallic powder first print material, a second feeder containing a metallic powder second print material, delivery means that sprays the print materials, a holder holding a substrate, and a controller. As the print materials are sprayed from the delivery means the controller, which is computerized, adjusts the relative disposition of the delivery means and substrate, and the controller controls the first and second feeders to each feed their print material to the delivery means, so that the print materials form a 3D article on the substrate wherein different parts of the 3D article have different characteristics due to the different print materials or proportions thereof being used for different portions of the 3D article.