Rotary Additive Manufacturing System for Continuous Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing systems, such as powder-bed-based laser melting systems, are not designed for high productivity and require time-consuming setup and maintenance, limiting their suitability for industrial mass production due to manual intervention and the need for a dust-free environment.
Innovation Solution
A rotary manufacturing unit with two identical manufacturing chambers that can be rotated to alternate between irradiation and maintenance positions, allowing continuous production without shutting down the system, with features like hermetically sealed covers, inert gas protection, and automated powder supply and removal to maximize irradiation time and equipment efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional powder-bed-based laser melting systems are used for individual pieces and prototypes, then manufacturing precision and quality can be maintained, but productivity is limited and not suitable for industrial mass production
Solution Approach 1:
The system is divided into multiple independent manufacturing chambers (first manufacturing chamber, second manufacturing chamber) that can operate simultaneously or independently. Each chamber has its own substrate, doctor blade, and cover, allowing parallel production of multiple layers or components, thereby increasing overall system productivity without compromising manufacturing precision
Solution Approach 2:
The rotary manufacturing unit enables continuous operation by rotating between different manufacturing chambers. While one chamber is undergoing maintenance or powder replacement, another chamber can continue the laser melting process, ensuring continuous useful action and maximizing productivity without idle downtime
2Adaptability or versatility
If manual powder removal and cleaning is performed in conventional systems, then powder material can be changed, but the system becomes unavailable and productivity is reduced during maintenance
Solution Approach 1:
The hermetically sealed covers with integrated powder removal mechanisms allow for preliminary preparation and containment of powder removal operations. The system can pre-position removal tools and maintain sealed environments, enabling rapid powder changes without compromising system availability or requiring extended downtime
Solution Approach 2:
Multiple manufacturing chambers allow one chamber to undergo maintenance while others continue production. The rotary mechanism ensures continuous operation by switching between chambers, maintaining system availability and productivity during powder material changes
3Object-affected harmful factors
If manual powder removal using protective devices is required, then operator safety can be ensured, but the operation becomes time-consuming and cost-intensive
Solution Approach 1:
The harmful factor (metal powder dust) is extracted and contained within the sealed manufacturing chambers. The hermetically sealed covers isolate the powder from the external environment, eliminating the need for operators to wear protective equipment during maintenance operations and significantly reducing maintenance time
Solution Approach 2:
The hermetically sealed cover acts as an intermediary barrier between the operator and the harmful metal powder dust. This intermediate sealed environment allows maintenance operations to be performed safely and efficiently without direct operator exposure to dust, reducing both safety risks and time loss
4Reliability
If the system is shut down for maintenance and powder replacement, then proper cleaning can be performed, but laser and optical units become unavailable
Solution Approach 1:
The system segments maintenance operations into individual chambers. Each manufacturing chamber can be maintained independently while others continue operation, allowing proper cleaning and powder replacement without shutting down the entire system, thus maintaining laser unit availability and productivity
Solution Approach 2:
The rotary manufacturing unit with multiple chambers ensures continuous useful action during maintenance. While one chamber undergoes cleaning and powder replacement, the laser and optical units can continue operating in other chambers, maintaining availability and preventing productivity loss
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 continuous production of layered products, maximizing laser operation time, reducing maintenance downtime, and improving overall equipment efficiency, making the system suitable for industrial mass production without the need for personal protective equipment during operation.
Implementation Method 1
a laser beam effects a melting and welding of the metal powder particles to form a quasi-solid metal
Implementation Method 2
selective laser melting, can be understood in that a thin layer of e.g. metal powder is spread onto a substrate and then fused or hardened by a laser beam
Implementation Method 3
a first doctor blade configured to apply a powder layer on a first substrate and the second manufacturing chamber comprises a second doctor blade configured to apply a powder layer on a second substrate
Implementation Method 4
The rotary manufacturing unit is configured to be rotatable into a first position in which the first manufacturing chamber is positioned for irradiating the powder layer on the first substrate and the second manufacturing chamber is positioned for enabling an opening of the second cover
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to an additive manufacturing system for applying a powder layer to a substrate and a manufacturing method using such additive manufacturing system. The additive manufacturing system comprises a rotary manufacturing unit. The rotary manufacturing unit comprises a first manufacturing chamber and a second manufacturing chamber. The first manufacturing chamber comprises a first openable cover and the second manufacturing chamber comprises a second openable cover. The first manufacturing chamber comprises a first doctor blade configured to apply a powder layer on a first substrate and the second manufacturing chamber comprises a second doctor blade configured to apply a powder layer on a second substrate. The rotary manufacturing unit is configured to be rotatable into a first position in which the first manufacturing chamber is positioned for irradiating the powder layer on the first substrate and the second manufacturing chamber is positioned for enabling an opening of the second cover. The rotary manufacturing unit is also configured to be rotatable into a second position in which the second manufacturing chamber is positioned for irradiating the powder layer on the second substrate and the first manufacturing chamber is positioned for enabling an opening of the first cover.