3D Printing Roller Cleaning Mesh for Uniform Powder Layers
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Solution Overview
Problem
Conventional cleaning devices for rollers used in 3D object layerwise manufacturing, such as brushes and blades, cause surface degradation and reliability issues due to static buildup and non-uniform layer distribution of particulate build material.
Innovation Solution
A cleaning device with a perforated mesh surface that resiliently engages with the roller to intermittently remove build material through perforations, allowing it to fall back onto the build area or into a receiving chamber, maintaining uniform layer thickness and reducing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 3D printing methods are used, then manufacturing capability is achieved, but support structures are required which consume material and time
Solution Approach 1:
The system segments the printing process into multiple independent layers that can be selectively removed. The support structure is divided into removable temporary support layers that are separated from the final product, allowing the main object to be manufactured without permanent support material consumption.
Solution Approach 2:
The patent implements a process where temporary support layers are discarded after serving their structural purpose during manufacturing. These support layers are selectively removed from the final product, recovering material that would otherwise be wasted and reducing overall material consumption.
2Productivity
If conventional 3D printing methods are used, then manufacturing capability is achieved, but build chamber size is limited
Solution Approach 1:
The system transitions from traditional single-layer sequential printing to multi-layer parallel processing. By utilizing multiple build chambers or layers that can be processed simultaneously, the effective build volume is expanded without requiring a proportionally larger single chamber, thus increasing productivity while managing spatial constraints.
3Productivity
If multiple nozzles are used to improve productivity, then layer formation speed increases, but nozzle clogging probability increases
Solution Approach 1:
The printing system is segmented into multiple independent nozzle assemblies, each capable of operating autonomously. This segmentation allows for individual nozzle monitoring and maintenance without affecting the entire system, reducing the probability of complete system failure due to clogging while maintaining high productivity through parallel operation.
4Adaptability or versatility
If support structures are used, then overhanging features can be manufactured, but manufacturing time increases
Solution Approach 1:
Temporary support layers are pre-formed as integral parts of the multi-layer structure during the manufacturing process itself, rather than being added separately afterward. This preliminary action allows support structures to be in place during critical manufacturing phases and then quickly removed, reducing total manufacturing time while maintaining the ability to produce overhanging features.
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
Ensures reliable and uniform distribution of build material layers by effectively removing adhered material from the roller surface without causing wear, thus enhancing the quality and consistency of 3D object production.
Implementation Method 1
The jet of material is deposited and cured to form a layer of the object
Data Source
Figure 1~2
Figure 3A~5
Figure 6A~7
AI summary
Provided is an apparatus for the layerwise manufacture of one or more 3D objects from particulate build material, wherein the apparatus comprises a build area (12) within a work surface (8) and over which the one or more 3D objects are to be formed, wherein the build area (12) represents the surface of the topmost layer, the apparatus comprising: a dosing device (60) configured to provide an amount of build material to the work surface (8); a roller (32) configured to pass over the build area (12) while rotating about an axis of rotation to distribute the dosed amount of the build material over the build area (12) to form a layer, the axis of rotation being perpendicular to the direction of distribution; and a cleaning device (34) comprising a cleaning portion extending parallel to the axis of rotation, wherein the cleaning device (34) comprises a plurality of perforations (P) comprised at least within the cleaning portion, the perforations (P) extending from a cleaning surface (46) of the cleaning portion to an opposite surface of the cleaning portion opposite the cleaning surface (46); wherein the cleaning surface (46) is configured to at least intermittently engage against the roller (32) surface while the roller (32) rotates, and wherein the perforations (P) are configured to allow build material to pass from the roller (32) through the cleaning portion to the opposite surface while the cleaning surface (46) is in engagement with the roller (32) surface. A method of operation is also provided.