Rotating Annular Build Head for Powder Bed Fusion

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Solution Overview

Problem

Conventional powder bed fusion additive manufacturing systems face inefficiencies when producing annular-shaped parts due to wasted unconsolidated powder and non-productive build time, as they are designed for rectangular or square geometries, leading to increased costs and inefficiencies.

Innovation Solution

A powder bed fusion additive manufacturing system with a rotating annular build plate and a multi-function build head that includes a powder delivery mechanism, recoater, optical array, and gas manifold, which ensures even powder distribution and energy delivery across the annular build plate, allowing for continuous, helical layer formation and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a rectangular or square build plate is used for PBF additive manufacturing, then the system can support a wide variety of build shapes, but large amounts of unconsolidated powder accumulate in the annulus of annular-shaped builds, representing waste

Engineering Contradiction:

Improveability to support various build shapesVSAvoidunconsolidated powder waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent inverts the conventional approach by making the build plate rotate instead of moving the laser/energy source in a stationary rectangular frame. This inversion allows the build plate to rotate and deposit material in a spiral pattern, eliminating the need for large rectangular build areas and reducing unconsolidated powder waste to minimal amounts required for the spiral path.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces dynamic rotation of the build plate, transforming the static rectangular build plate into a rotating annular structure. This dynamic element enables continuous spiral deposition and eliminates the waste associated with stationary rectangular build plates by concentrating material deposition only where needed in the spiral path.

Inventive Principle:

Principle #15Dynamics

2Device complexity

If a rectangular or square build plate is used, then the system structure is simple, but non-productive build time increases due to wasted volume of unconsolidated powder

Engineering Contradiction:

Improvebuild plate structureVSAvoidnon-productive build time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The rotating annular build plate enables continuous spiral deposition without interruptions for repositioning or handling large amounts of powder. The continuous rotation maintains productive action throughout the build process, eliminating non-productive time associated with managing unconsolidated powder in conventional rectangular systems.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If conventional PBF systems are used for annular parts, then the manufacturing process is straightforward, but the volume of unconsolidated powder accumulates in the annulus, increasing costs

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidunconsolidated powder in annulus

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent segments the build process into continuous spiral layers deposited by rotating annular build plate, rather than processing the entire annular area at once. This segmentation allows material to be deposited only where needed in the spiral path, eliminating the accumulation of unconsolidated powder in the annulus region.

Inventive Principle:

Principle #1Segmentation

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 system effectively reduces waste and non-productive build time by utilizing a rotating annular build plate and optimized energy delivery, enabling efficient production of annular-shaped parts with consistent consolidation and reduced costs.

Implementation Method 1

an optical array positioned over the build area on the build plate, wherein the optical array is configured to project energy onto the build powder bed to form a melt pool in the build powder bed

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

Build powder from the melt pool is selectively sintering, using energy from the optical array, to form a layer of a consolidated part

Methodology Applied

Scientific EffectSelective laser sintering: Selective Laser Sintering

Data Source

PatentUS20250001683A1Powder bed fusion additive printer build head

Publication Date: 2025.01.02 RTX CORP

AI summary

A build head for a powder bed fusion (PBF) additive manufacturing system includes a powder delivery mechanism configured to deliver build powder to a build area of an annular build plate to form a build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation. A recoater is configured to provide even distribution of the build powder in the build powder bed and an optical array is positioned over the build area on the build plate to project energy onto the build powder bed to form a melt pool in the build powder bed.