3D Printer Powder Dispensing System for Metal Parts
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Solution Overview
Problem
Current 3D printing technologies are expensive and limited in material selection, particularly for producing metal parts, as they often require impractical liquid metal dispensing and struggle with achieving uniformity and porosity in powder-based methods.
Innovation Solution
A method using a build powder and a support powder, where the build powder is strongly bound by a binder, allowing for layer-by-layer patterning and subsequent removal of the support powder to create a 3D object, with a 3D printer apparatus capable of dispensing these powders in a controlled sequence to form the target shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid or gel substances are deposited and then cured, then the 3D printing process can be completed, but the material selection is limited and the curing operation prolongs the process
Solution Approach 1:
The patent changes the physical state parameter of the binder from liquid/gel to powder form, and eliminates the curing operation entirely. The binder powder is applied dry and mixed with the build powder, removing the need for subsequent curing steps while maintaining the binding function.
Solution Approach 2:
The patent extracts and removes the curing operation from the 3D printing process. By using binder powder that activates through mixing rather than requiring curing, the process eliminates the additional curing step, reducing both time and complexity.
2Manufacturing precision
If bind powder and build powder are mixed thoroughly, then uniform printed objects are created, but the mixing process adds complexity and time
Solution Approach 1:
The binder powder is pre-positioned in specific locations within the build chamber before the build powder is deposited. This preliminary placement ensures that when the build powder is poured, the binder is automatically mixed in as the powder flows, eliminating the need for separate mixing operations.
Solution Approach 2:
The binder powder acts as an intermediary substance that is distributed throughout the build powder during the deposition process. This intermediary approach ensures uniform distribution without requiring separate mixing steps, as the binder is incorporated during the layer formation itself.
3Adaptability or versatility
If metals are dispensed as liquids, then 3D printing can be performed, but the high melting temperatures and oxidation tendency make this impractical
Solution Approach 1:
The patent changes the physical state of the metal material from liquid (requiring high temperature melting) to powder form. This parameter change allows metals to be processed at lower temperatures, eliminating the oxidation and high temperature handling issues while maintaining the ability to 3D print metal parts.
Solution Approach 2:
The patent uses a composite approach with build powder and binder powder combined in a single chamber. This composite material system allows for versatile material selection including metals, as the binder powder system can accommodate various metal powders without requiring liquid metal processing.
4Ease of operation
If unbound build powder is removed, then the printed object can be freed from surrounding powder, but the removal process becomes difficult when bind powder and build powder are dissimilar
Solution Approach 1:
The binder powder is applied locally to specific areas of the build powder where binding is needed. This localized application ensures that only the necessary portions are bound, making the removal of unbound powder easier while maintaining structural integrity where required.
Solution Approach 2:
The patent uses parameter changes in the binder powder characteristics to ensure compatibility with build powder. By adjusting the binder powder properties (such as particle size, composition, and activation characteristics), the system achieves uniform mixing and easy separation while maintaining material compatibility.
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 enables the cost-effective and efficient production of 3D objects by using pourable powders that remain in solid form during processing, preventing shape distortion and allowing for the creation of complex shapes without the need for extensive curing operations, thus overcoming material limitations and process complexity.
Implementation Method 1
the binder is applied to layers of build and support powder and permitted to cure, thereby forming the object of build powder and binder
Implementation Method 2
The build powder and the support powder are dispensed in a sequence of layers of build powder patterned with support powder
Implementation Method 3
Finally, the support powder is removed from the formed object
Data Source
AI summary
An apparatus for dispensing build powder and support powder, in a sequence of layers, and having a frame and a container. Also, a build powder pourer is at least partially filled with build powder and a support powder pourer at least partially filled with support powder, each of the pourers having a dispensing opening and a dispensing plug, controllably covering the dispensing opening. Further, a pourer-movement and dispensing plug-actuating assembly is supported by the frame over the container and includes a movement element that is selectively attachable to the build powder pourer and alternately to the support powder pourer and also capable to controllably move an attached pourer in three orthogonal dimensions and to control the dispensing plug. In addition, at least one docking station for holding a first one of the pourers; and a computing assembly controls the pourer-movement and dispensing plug-actuating assembly to create a target shape.