Printing Block Storage Chamber for Stable Viscous Material Deposition
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Solution Overview
Problem
Existing additive manufacturing technologies using powdered materials face challenges with inertia-related manufacturing defects such as porosity and burrs due to transient flow regimes, particularly in non-Newtonian materials, leading to increased manufacturing time and costs.
Innovation Solution
A printing block with a storage chamber and pumping mechanism that compensates for inertia by adjusting the volume and flow rate of viscous material, using actuators and pressure control to ensure consistent deposition, including features like a shutter and secondary deposition means to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If powder or granules are used as material instead of wire, then operating cost is reduced (6 to 10 times lower), but flow control becomes more difficult and inertia increases causing manufacturing defects
Solution Approach 1:
The patent implements a variable speed drive system that dynamically adjusts the screw conveyor speed based on real-time flow rate requirements. This allows the system to respond quickly to changes in deposition needs while maintaining precise control over powder flow, resolving the contradiction between cost efficiency and flow control precision
Solution Approach 2:
The system incorporates flow rate sensors and control algorithms that continuously monitor material flow and adjust screw conveyor speed accordingly. This feedback mechanism ensures precise flow control despite using inexpensive powder materials, eliminating manufacturing defects while maintaining low operating costs
2Loss of time
If screw conveyor speed is increased to compensate for inertia at cycle start, then material delivery delay is reduced, but speed variations cause inertia problems and manufacturing defects
Solution Approach 1:
The system pre-heats the powder material and pre-positions the screw conveyor at optimal speed before the deposition cycle begins. This preliminary preparation ensures that material is ready for immediate deposition without delays, while the controlled acceleration profile prevents inertia-related defects during speed transitions
Solution Approach 2:
The variable speed drive system dynamically adjusts screw conveyor speed during the deposition process, accelerating smoothly at cycle start and maintaining optimal speed throughout. This dynamic control eliminates both delivery delays and inertia-induced manufacturing defects
3Manufacturing precision
If heating is advanced to coincide with relative movement, then material delivery timing is improved, but computing resources are significantly consumed and algorithms become cumbersome
Solution Approach 1:
The system pre-heats the powder material before deposition begins and maintains it at optimal temperature throughout the process. This preliminary heating action ensures material is ready for immediate deposition with precise timing, while the simplified thermal control algorithm reduces computing resource requirements
Solution Approach 2:
The heating system automatically maintains material at the required temperature through feedback control, eliminating the need for complex coordinated heating algorithms. This self-regulating thermal management improves deposition timing while reducing computational complexity
4Productivity
If rapid relative movement occurs between printing platform and printing block to change deposition area, then cycle transition is faster, but porosity and burrs are generated due to inertia
Solution Approach 1:
The variable speed drive system dynamically adjusts screw conveyor speed during rapid transitions between deposition areas. By matching the acceleration and deceleration profiles with the platform movement, the system maintains continuous, defect-free material flow even during fast cycle transitions
Solution Approach 2:
The system anticipates rapid transitions and pre-adjusts material flow rate and heating parameters before the movement occurs. This preliminary adjustment prevents porosity and burrs by ensuring material is ready for immediate deposition when the transition completes, maintaining quality while enabling fast cycle changes
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
The solution provides precise control over material flow, reducing manufacturing defects and maintaining consistent throughput, resulting in higher print quality and reduced production costs for powdered materials.
Implementation Method 1
a gear mechanism arranged in the conduit, the gear mechanism driving the viscous material from the storage chamber to discharge it towards the dispensing means
Implementation Method 2
the material to be melted can be in the form of a wire packaged on a reel, or in the form of a powder (or granules)... the material is then melted to adopt a viscous state
Data Source
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AI summary
A printing unit (2) for an additive manufacturing machine (1) using viscous material obtained from powder, the printing unit (2) comprising: - feed means (22) for supplying viscous material; - deposition means (23) for depositing viscous material, the printing unit (2) also comprising: - at least one storage chamber (24) for storing viscous material, the chamber being delimited by an internal wall (241) having at least one movable portion (242), the chamber defining a storage space (V) and being inserted between the feed means (22) and the deposition means (23).