Reciprocating Cutter Powder Production for Uniform 3D Printing Particles
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Solution Overview
Problem
Current powder production methods for additive manufacturing yield particles with inconsistent size distributions and low uniformity, leading to inefficiencies in 3D printing processes, as only a small percentage of produced powder is suitable for additive manufacturing due to large or non-uniform particles.
Innovation Solution
A method involving a reciprocating cutter system that repeatedly contacts an elongated workpiece to produce particles with a narrow size distribution, where at least 95% of the particles have a diameter ranging from 10 μm to 200 μm, and a system comprising a cutter, driver, and controller to control the cutting process, ensuring uniformity and low porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If atomization techniques are used to produce powder, then a large quantity of powder can be produced, but the particle size distribution is wide and most particles are too large or non-uniform for additive manufacturing
Solution Approach 1:
The invention segments the powder production process into two distinct stages: first producing a large quantity of powder via atomization, then selectively processing this powder through a classification system that separates particles into size-based groups. This segmentation allows the system to maintain high production volume while achieving precise particle size control for additive manufacturing applications.
Solution Approach 2:
The invention applies local quality by creating different particle size distributions in different portions of the produced powder. The classification system sorts particles into specific size ranges (e.g., 15-45 μm, 45-75 μm, 75-106 μm) so that each portion of the powder has the precise local quality needed for specific additive manufacturing requirements, while the overall system maintains high production capacity.
2Adaptability or versatility
If atomization produces particles ranging from 0 μm to 500 μm, then a broad size range is achieved, but only 20%-40% of particles are suitable for additive manufacturing
Solution Approach 1:
The invention implements discarding and recovering by separating particles that fall outside the desirable size range for additive manufacturing and redirecting them back into the production process. The classification system identifies and sets aside oversized or undersized particles, which can then be reprocessed or combined with other fractions to maximize the usable yield from the original atomization batch.
Solution Approach 2:
The invention applies parameter changes by adjusting the classification thresholds and sorting parameters of the classification system to optimize for different additive manufacturing requirements. By dynamically changing the size range parameters and classification criteria, the system can adapt to produce different proportions of usable powder while maintaining high overall productivity.
3Manufacturing precision
If large portions of powder must be used for other applications, then production efficiency decreases, but maintaining narrow size distribution requires additional processing
Solution Approach 1:
The invention maintains continuity of useful action by implementing a continuous classification and sorting process that operates simultaneously with the atomization production. Rather than batch-processing powder to achieve narrow size distribution, the system continuously classifies particles as they are produced, ensuring that usable powder is immediately available for additive manufacturing without interrupting the production flow or requiring separate processing steps.
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 method achieves a high percentage of particles within a targeted size range, improving the flow characteristics and operational efficiency of 3D printing machines by producing dense, uniformly sized, and shaped particles suitable for additive manufacturing.
Implementation Method 1
mechanically attriting a source or feedstock with a reciprocating cutter
Data Source
AI summary
A powder production method includes providing an elongated workpiece and repeatedly contacting an outer surface of the elongated workpiece with a reciprocating cutter according to a predetermined at least one frequency to produce a powder. The powder includes a plurality of particles, wherein at least 95% of the produced particles have a diameter or maximum dimension ranging from about 10 μm to about 200 μm. A system for producing powders having a plurality of particles including a cutter and at least one controller is also provided herein.