Rotatable Powder Container for Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing methods face challenges in consistently removing a predetermined amount of powder from a powder storage, as the quality of the powder (humidity, composition, size, etc.) affects the amount removed, leading to inconsistencies in powder distribution and repeatability.

Innovation Solution

A method and apparatus involving a rotatable powder container with a spatially separated exit and opening, allowing for a fixed amount of powder to be ejected during specific rotational angles, ensuring a precise and repeatable powder distribution on the worktable, with optional dual containers for different materials and a heater for drying, and a guide plate for efficient powder placement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a distribution member is moved a predetermined distance into a powder supply to transfer powder, then powder can be transferred from storage to the working area, but the powder quality (humidity, composition, size) affects the amount removed, leading to inconsistent powder distribution

Engineering Contradiction:

Improveamount of powder transferredVSAvoidpowder distribution consistency

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent changes the operational parameters from moving the distribution member to rotating the container at controlled speeds. The rotation speed (5-50 RPM) and angular position (0-360 degrees) are precisely controlled parameters that determine the exact amount of powder ejected, making the process independent of powder quality variations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical sliding movement of the distribution member with a rotational mechanical system. The container rotates on an axis, and powder is ejected through controlled rotation rather than linear movement, allowing for more precise control through rotational speed and angular position.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If powder quality varies (humidity, composition, size), then the amount of powder removed from storage becomes inconsistent, but using a controlled rotation system with spatially separated openings ensures fixed amount ejection

Engineering Contradiction:

Improverepeatability of powder amountVSAvoidcontainer structure with spatially separated openings

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The container is segmented into distinct functional zones: a first opening for powder input, a second opening for powder ejection, and a rotation axis. This segmentation allows each zone to perform its specific function independently, with the spatial separation ensuring that powder flow paths are controlled and measurable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rotatable container serves multiple functions: it stores powder, controls powder flow rate through rotation speed, measures the amount of powder ejected through angular position, and can be refilled without removing the container from the system. This multi-functionality reduces the need for additional separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This approach allows for precise control of powder distribution, improved repeatability, and the ability to use different materials in various parts of the 3D article, reducing material costs and building time, while maintaining efficient powder drying without powder ejection.

Implementation Method 1

rotating said powder container... ejecting a fixed amount of powder from said powder container during at least one predetermined segment of rotational angles

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

providing a heater in at least one of said powder containers for drying said powder

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS9126167B2Powder distribution in additive manufacturing

Publication Date: 2015.09.08 ARCAM AB

AI summary

An additive manufacturing method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Providing at least one rotatable powder container above said work table, said powder container comprising at least one exit for providing powder to a powder table arranged beside said work table, at least one opening inside said container is spatially separated from and connected to said at least one exit. Ejecting a fixed amount of powder from said powder container during at least one predetermined segment of rotational angles of said powder container, from the exit of said powder container onto said powder table, wherein said fixed amount is determined by the shape and size of the at least one opening inside said container. Distributing said powder onto said work table with a powder distributor.