Ring Material Supply Chamber With Optical Positioning for Large 3D Builds
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Solution Overview
Problem
Existing additive layer production methods, particularly for large workpieces, face inefficiencies and quality issues in producing three-dimensional workpieces.
Innovation Solution
A process chamber apparatus with a ring-like material supply unit, gas flow and solidification devices, and a positioning system that allows for uniform material distribution, precise positioning, and safety controls, enhancing production efficiency and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a process chamber is moved around in three dimensions to build separate portions of a large object, then productivity is improved for large workpieces, but manufacturing precision deteriorates due to positioning challenges
Solution Approach 1:
The patent replaces mechanical positioning systems with an optical positioning system. A light source generates reference light beams that form reference planes, and light detectors on the process chamber detect these beams to determine position and orientation. This optical substitution eliminates mechanical wear and positioning errors, achieving high precision (sub-millimeter to micrometer level) while maintaining the mobility needed for large workpiece production.
Solution Approach 2:
The patent introduces light beams as an intermediary between the fixed reference frame and the moving process chamber. The reference light beams serve as a mediator that transfers positional information without requiring direct mechanical contact or complex mechanical linkages, enabling precise positioning of the process chamber during additive manufacturing of large workpieces.
2Manufacturing precision
If material is supplied uniformly across the carrier surface, then manufacturing precision is improved, but device complexity increases due to additional positioning and control systems
Solution Approach 1:
The patent replaces complex mechanical positioning systems with a simplified optical positioning system. By using light beams as references and light detectors to sense position, the system achieves precise material distribution control without requiring complex mechanical actuators, feedback sensors, or control mechanisms traditionally needed for such precision.
Solution Approach 2:
The optical positioning system serves multiple functions simultaneously: it determines the position of the process chamber, orients the material supply unit, and enables precise material deposition. This multi-functionality reduces overall device complexity compared to having separate systems for each function.
3Productivity
If the process chamber is moved to different positions to access various areas of the carrier, then productivity is improved for large workpieces, but reliability deteriorates due to potential positioning errors and safety risks
Solution Approach 1:
The patent replaces mechanical positioning with optical positioning to improve reliability. The optical system using reference light beams and light detectors provides consistent, repeatable positioning without mechanical wear, backlash, or drift, ensuring the process chamber reliably returns to correct positions during additive manufacturing of large workpieces.
Solution Approach 2:
The optical positioning system provides continuous feedback about the process chamber's position and orientation. The light detectors detect reference light beams and provide positional information that can be used for real-time correction and verification, enhancing reliability through feedback control.
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 apparatus ensures uniform material distribution, precise positioning, and safety, thereby improving the efficiency and quality of large three-dimensional workpiece production.
Implementation Method 1
a gas flow device adapted to form a flow of gas above a surface of the area of the material layer that is to be solidified by the solidification device
Implementation Method 2
a heating unit adapted to heat up the material supplied on the carrier
Implementation Method 3
the positioning unit comprises a light source adapted to generate one or more light beams for a reference line and/or a reference plane serving as a reference for a position and/or orientation of the process chamber
Implementation Method 4
the one or more sensors comprise one or more light detectors, in particular laser radiation detectors; wherein the light detectors are adapted to detect the one or more light beams
Data Source
Figure 1a~1c
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AI summary
We describe a process chamber, an apparatus, a modular system, a method, a safety device, a positioning system and a system for producing a three-dimensional workpiece and/or for use thereof when producing a three-dimensional workpiece. The process chamber for producing the three-dimensional workpiece via an additive layer construction method comprises: a material supply unit comprising a substantially ring-like shaped end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, material to a carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and an opening at the first side of the process chamber for processing, by the process chamber, the material supplied on the carrier in order to produce the three-dimensional workpiece, wherein the substantially ring-like shaped end portion surrounds the opening.