Rotatable Ring Powder Dispenser for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in efficiently controlling the dispensing and compaction of powders during the 3D printing process, leading to inefficiencies in forming objects and reducing overall throughput.
Innovation Solution
The proposed solution involves a dispensing system with rotatable rings and a cap plate, allowing for independent control of powder dispensing paths and rates, enabling precise and high-throughput dispensing of powders onto a build platform, with a screw conveyor for compacting and distributing powder, and a controller to manage the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder dispensing systems are used, then the structure is simple, but the manufacturing precision and control over powder placement are insufficient
Solution Approach 1:
The dispensing system is divided into multiple independent rotatable rings, each capable of selective rotation to control powder discharge at different positions. This segmentation allows precise control over where powder is deposited on the build platform while maintaining a modular structure that can be manufactured and assembled from individual components.
Solution Approach 2:
The rings are designed to be rotatable rather than fixed, allowing dynamic adjustment of powder dispensing positions during the additive manufacturing process. This dynamic capability enables precise control over powder placement patterns without requiring complex fixed positioning mechanisms for each dispensing location.
2Productivity
If powder is dispensed continuously to increase throughput, then productivity improves, but powder consumption increases and compaction control deteriorates
Solution Approach 1:
The dispensing system uses periodic rotation of the rings to dispense powder only when needed at specific positions, rather than continuous dispensing. This periodic action allows the system to maintain high throughput by rapidly cycling through dispensing positions while minimizing powder consumption by keeping the powder flow closed when not actively dispensing.
Solution Approach 2:
Different regions of the build platform receive powder selectively based on the rotation position of the rings. This local quality approach ensures powder is deposited only where required for the current layer being built, reducing overall powder consumption while maintaining productivity by avoiding unnecessary powder dispensing to areas that don't need material.
3Adaptability or versatility
If multiple powder paths are used to increase dispensing flexibility, then adaptability improves, but device complexity increases
Solution Approach 1:
Each rotatable ring serves multiple functions: it acts as a structural component, a positioning mechanism, and a powder dispensing control element. This multi-functionality provides high dispensing flexibility and adaptability for creating different object geometries while avoiding the need for separate specialized components for each function, thereby limiting the increase in overall system complexity.
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 solution enhances the efficiency of forming objects by allowing for controlled powder placement and compaction, increasing throughput and reducing powder consumption by enabling selective and precise dispensing.
Implementation Method 1
The powder conveyor can further include a screw conveyor coaxial with the longitudinal axis of the powder conveyor and rotatable about the longitudinal axis of the powder conveyor such that, when the screw conveyor rotates, the screw conveyor moves the powder carried within the powder conveyor along the length of the powder conveyor.
Implementation Method 2
an energy source to apply energy to the powder dispensed on the top surface of the platen to form a fused portion of the powder
Implementation Method 3
Each ring is configured to be independently rotatable such that the at least one ring opening of the respective concentric ring is movable into or out of alignment with the at least one cap plate opening.
Data Source
AI summary
An additive manufacturing apparatus includes a dispensing system positionable over a platen to deliver a powder, an actuator to move the dispensing system along a scan axis, and an energy source to fuse a portion of the powder. The dispensing system has a hopper to hold the powder and a dispenser. The dispenser includes a channel extending along a longitudinal axis from a proximal end to a distal end. The proximal end of the channel of the dispenser is configured to receive the powder from the powder source. A powder conveyor is positioned within the channel to move the powder from the proximal end along a length of the channel, and a plurality of apertures are arranged along the longitudinal axis of the channel. The dispenser is configured such that flow of powder through each aperture is independently controllable.