Retrofit Build Piston for Powder Bed Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing machines with large build areas waste powdery material when producing small objects, as they require more material than necessary, reducing economic efficiency.
Innovation Solution
A retrofit device that reduces the active build area and powder feed area by using smaller build and feed pistons with covers that can be quickly attached and detached, allowing for efficient use of a smaller building space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large build area is used in additive manufacturing machines, then the machine can manufacture larger objects, but powdery material is wasted when producing small objects
Solution Approach 1:
The build container is segmented into a fixed portion and a movable build platform portion. The build platform can be selectively removed and replaced, allowing the effective build area to be segmented and adjusted based on object size requirements. This segmentation enables using only the necessary portion of the build area, reducing powder material waste for small objects while maintaining full build area capability for larger objects.
Solution Approach 2:
The build platform is made dynamic through quick-release attachment mechanisms that allow rapid removal and replacement. This dynamic capability enables the build area to be adaptively adjusted between different sizes depending on the manufacturing requirements, transforming a static large build area into a dynamically adjustable configuration that matches the actual object size being manufactured.
2Adaptability or versatility
If a large build area machine is used for small objects, then the machine maintains full capability, but the economic efficiency is reduced
Solution Approach 1:
The build platform is segmented as a separate, removable component that can be quickly exchanged. This allows the machine to be reconfigured for different build area sizes without permanent modifications, enabling efficient production for small objects while maintaining the option to use full build area capability when needed, thereby improving economic efficiency across different production scenarios.
Solution Approach 2:
The effective build area parameter is changed by removing and replacing the build platform. This simple parameter change allows the machine to transition between full-capability mode and optimized small-object mode, adjusting the operational parameters to match production requirements and improve economic efficiency without sacrificing adaptability.
3Loss of substance
If the build area is permanently reduced, then material waste is minimized, but the machine cannot manufacture larger objects
Solution Approach 1:
The build system is segmented into a permanent container structure and a removable build platform. This segmentation allows the platform to be customized or removed entirely, enabling the build area to be precisely matched to object size requirements. When manufacturing small objects, a smaller platform is used to minimize powder waste; when larger objects are needed, the full build area is restored by installing an appropriate platform.
Solution Approach 2:
The build area configuration is made dynamic through the quick-release mechanism that enables rapid platform exchange. This dynamic reconfigurability allows the system to adapt between different build area sizes based on production needs, preventing permanent reduction while achieving material efficiency through selective use of appropriate build areas for each manufacturing task.
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 efficient use of a smaller building space and reduced material usage, improving economic efficiency by allowing the machine to be easily modified for smaller objects without altering the standard build area.
Implementation Method 1
a build piston (20) having a top presenting a build surface (4) upon which an object is built and a bottom
Implementation Method 2
The shaft has sidewalls which are sealingly and slideably engaged by the piston
Implementation Method 3
The cover attachment mechanism can include quick release clamps which engage with the container sidewalls
Implementation Method 4
an object is built up in layerwise fashion using a powder or similar fluent material
Implementation Method 5
layerwise solidification of a powdery building material at locations corresponding to the object in the respective layers
Data Source
AI summary
A standard powder bed fusion additive manufacture apparatus is provided with a device to modify the building space, including the powder feed for the building space, yielding a reduction in the active build area, with a concomitant reduction in the adjacent powder supply. A retrofit kit or assembly which is quickly emplaced on the existing equipment with little modification of the regular building space is provided, and is therefore readily removable when the building space is to be returned to its original condition. One advantage is the relatively quick manner in which the building space can be modified. A reduced area build piston is slideably received in a shaft depending from a cover that is emplaceable on the unmodified build area. The build piston moves with the pre-existing build platform. A like arrangement is provided for the feed container.