Rotating Build Platform for Continuous Powder Bed Consolidation
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Solution Overview
Problem
Existing additive manufacturing systems with rotating build platforms face increased costs and fabrication time due to the need for precise coordination of multiple actuators and sequential operation of recoaters and energy sources, which limits manufacturing efficiency.
Innovation Solution
An additive manufacturing system with a rotating build platform that utilizes a first actuator assembly to rotate the platform at a first speed and a second actuator assembly to translate it along a rotation axis at a second speed, allowing simultaneous operation of a recoater and consolidation device to distribute and consolidate particulate, reducing fabrication time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple linear and rotary actuators are used to move the build platform in different directions, then the build platform can be precisely positioned, but the system complexity and cost increase
Solution Approach 1:
The patent combines multiple actuator functions into a single rotating build platform mechanism. The platform's rotation about its central axis simultaneously achieves both radial and axial positioning of the build area, eliminating the need for separate linear and rotary actuators while maintaining positioning precision.
Solution Approach 2:
The rotating build platform serves multiple functions: it positions the build area radially, controls axial movement, and enables sequential access for both particulate deposition and consolidation operations. This multi-functionality reduces the overall number of actuators required in the system.
2Manufacturing precision
If the recoater and focused energy source are operated sequentially, then the particulate can be properly distributed and consolidated, but the fabrication time increases
Solution Approach 1:
The system performs preliminary particulate distribution by the recoater before consolidation begins. The rotating platform allows the recoater to deposit and spread particulate material in advance, preparing the build area for subsequent consolidation operations without requiring sequential operation that would halt production.
Solution Approach 2:
The rotating build platform enables continuous operation by allowing the recoater and consolidation device to operate in different angular positions simultaneously. As the platform rotates, material distribution and consolidation occur continuously without interruption, maintaining both quality and speed.
3Productivity
If the build platform rotates at high speed, then the fabrication time is reduced, but the coordination difficulty between actuators increases
Solution Approach 1:
The rotating build platform is self-sufficient in achieving positioning functions through its own rotation. The platform's rotational motion inherently provides both radial and axial positioning without requiring external actuators to coordinate complex movements, simplifying the control system even at high speeds.
Data Source
AI summary
An additive manufacturing system may include a build platform configured to receive a particulate, a particulate dispenser configured to deposit the particulate onto said build platform, a consolidation device configured to consolidate at least a portion of the particulate to form a component, a first actuator assembly configured to rotate said build platform about a rotation axis at a first speed, and a second actuator assembly configured to rotate said shaft about the rotation axis at a second speed different from the first speed.