Rotating Build Platform for Large-Scale Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing systems are limited by the size of the powder bed, which restricts the size of objects that can be built, and face challenges in achieving large-scale production with precision and efficiency while minimizing material waste.
Innovation Solution
The use of a rotating build platform and mobile build unit with a powder recoating mechanism, along with a positioning mechanism allowing two- or three-dimensional movement and rotation, enables the construction of large-scale objects by eliminating the need to lower the build platform, and incorporates a compensation scheme for rotational movement to maintain scan quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the powder bed size is increased to build larger objects, then the object size is improved, but the scan quality deteriorates due to large angle of incidence and the system weight exceeds stepper capabilities
Solution Approach 1:
The system divides the build process into segments by rotating the build platform in angular increments (e.g., 1 degree per layer) and reconstructing the object at different angular positions. This allows the laser to always scan at optimal angles while building large-diameter objects that would otherwise require excessive powder bed sizes.
Solution Approach 2:
The patent introduces rotational movement as an additional dimension to the traditional linear build process. By rotating the build platform and reconstructing at different angular positions, the system transforms a 3D printing problem into a 4D process (x, y, z, theta), enabling large object construction without increasing powder bed dimensions.
2Loss of substance
If conventional additive manufacturing is used to build large objects, then material waste is reduced compared to subtractive methods, but production time increases and precision is compromised
Solution Approach 1:
The system performs continuous useful action by simultaneously executing multiple operations: laser scanning, platform rotation, powder deposition, and layer reconstruction occur in an integrated continuous process rather than sequential steps, reducing idle time and improving productivity.
Solution Approach 2:
The build platform is pre-positioned at specific angular orientations before each scanning operation, and powder layers are pre-spread and leveled before laser processing begins. This preliminary preparation eliminates positioning delays during the actual manufacturing process.
3Quantity of substance
If the build platform is lowered to accommodate additional layers in conventional systems, then more material can be processed, but the system complexity and weight increase beyond stepper capabilities
Solution Approach 1:
The system replaces the static, vertically-lowering build platform with a dynamic, rotatable platform. Instead of moving the platform vertically to accommodate more layers, the platform rotates horizontally, allowing continuous material processing without increasing vertical travel distance or mechanical 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 approach allows for the efficient production of large-scale, high-precision objects with reduced material waste and improved time efficiency, enabling the fabrication of complex components like turbine parts with enhanced precision and control over powder deposition.
Implementation Method 1
an irradiation emission directing device that directs an energy beam, for example, an electron beam or a laser beam, to sinter or melt a powder material
Implementation Method 2
Selective laser sintering, direct laser sintering, selective laser melting, and direct laser melting are common industry terms used to refer to producing three-dimensional (3D) objects by using a laser beam to sinter or melt a fine powder
Implementation Method 3
melting entails fully melting particles of a powder to form a solid homogeneous mass
Implementation Method 4
The use of a rotating build platform and mobile build unit with a powder recoating mechanism, along with a positioning mechanism allowing two- or three-dimensional movement and rotation
Implementation Method 5
incorporates a compensation scheme for rotational movement to maintain scan quality
Implementation Method 6
mobile build unit with a powder recoating mechanism
Data Source
AI summary
An additive manufacturing apparatus is provided and may include at least one build unit; a build platform; and at least one collector positioned on the apparatus such that the at least one collector contacts an outer surface of a build wall as the build wall is formed during a build. Methods are also provided for manufacturing at least one object.