3D Printer Curtain for Powder Leakage Control

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Solution Overview

Problem

Three-dimensional printing systems based on powder fusion face issues with air turbulences causing small powder particles to leave the print zone uncontrollably, leading to reduced part quality and increased maintenance due to powder leakage, which damages electronic and mechanical parts.

Innovation Solution

The implementation of a curtain mechanism attached to the printer carriage that moves in parallel to the print zone to reduce air movement and turbulence, ensuring that air disturbances are minimized during the printing process, and optionally using preheating to lower the energy required for fusing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the carriage moves quickly over the print zone to increase productivity, then printing speed improves, but air turbulences increase causing powder particles to leave the print zone uncontrollably

Engineering Contradiction:

Improveprinting speedVSAvoidpart quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

A curtain is introduced as an intermediary element between the carriage and the print zone. The curtain moves synchronously with the carriage and acts as a barrier to reduce air turbulences generated by carriage movement, thereby preventing powder particles from being disturbed while allowing the carriage to maintain high printing speed

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The curtain changes the airflow parameters in the print zone by reducing air movement and turbulence intensity. This parameter change allows the system to maintain high carriage speed while keeping powder particles stable on the print bed

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If smaller powder particles are used to improve manufacturing precision, then part quality improves, but powder particles become more susceptible to air turbulences and leave the print zone uncontrollably

Engineering Contradiction:

Improvepart qualityVSAvoidpowder leakage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The curtain serves as a protective intermediary that shields smaller powder particles from air turbulences. By reducing air movement in the print zone, the curtain prevents lightweight powder particles from being lifted and scattered, enabling the use of finer particles for higher precision printing

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The curtain creates a relatively inert atmospheric environment within the print zone by isolating it from external air movements. This controlled environment minimizes air turbulences that would otherwise disturb powder particles, allowing smaller particles to remain stable during the printing process

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Area of stationary object

If the carriage moves back and forth to print over the entire printer bed surface, then coverage improves, but air turbulences are generated causing powder to leak and damage electronic and mechanical parts

Engineering Contradiction:

Improveprint zone coverageVSAvoidpowder leakage

Core Design Contradiction:

Area of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The curtain acts as a moving barrier that travels with the carriage, creating a localized protected zone beneath the carriage. This intermediary structure prevents powder particles from being scattered by carriage-induced air turbulences while the carriage covers the entire print zone surface

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution adds a vertical dimension to the problem by introducing a curtain that hangs down from the carriage into the print zone. This three-dimensional approach creates a physical barrier that blocks horizontal air movements caused by carriage traversal, preventing powder leakage while maintaining full area coverage

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 significantly reduces powder leakage and maintains a cleaner printer environment, enhancing part quality and reducing maintenance needs by minimizing air turbulences and supporting the use of smaller powder particles, while also lowering the impact on electronics and extending filter life.

Implementation Method 1

The curtain is attached to a first side of the printer carriage and is arranged to move along with the printer carriage such that the curtain reduces air movement and turbulence in a print zone of the three-dimensional printer

Methodology Applied

Scientific EffectAir turbulence reduction: Turbulence

Implementation Method 2

optionally using preheating to lower the energy required for fusing

Methodology Applied

Scientific EffectPreheating: Heating

Data Source

PatentUS11207828B2Three-dimensional printer

Publication Date: 2021.12.28 PERIDOT PRINT LLC

AI summary

A three-dimensional printer comprising means for build material, a printer carriage and a curtain. The means for depositing the build material deposits same on a printing zone and/or on one or more build material layers deposited on the printing zone. The printer carriage is to move along a first axis over the printing zone and comprises means for treating the build material. The curtain is attached to a first side of the printer carriage with a first side of the curtain and/or configured to move along with the printer carriage such that the curtain covers at least an area of the print zone, wherein the area varies dependent on the moving of the printer carriage over the print zone.