Rotating Platform Vibration for Additive Manufacturing Powder Removal
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Solution Overview
Problem
Existing additive manufacturing processes, particularly powder bed fusion, face challenges in efficiently and safely removing excess powder from complex and heavy components, such as those used in gas turbines, due to the risk of ignition and explosion from residual powder particles.
Innovation Solution
An apparatus with a platform that can rotate and deflect independently around two orthogonal spatial directions, coupled with an actuation mechanism driven by pressurized inert gas, is used to remove excess powder. The apparatus is designed to operate within a sealed working space to minimize the risk of ignition and explosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual or simple mechanical tools are used to remove excess powder, then the removal process is simple and low-cost, but the process is time-consuming and labor-intensive
Solution Approach 1:
The apparatus employs a vibration generator that generates vibrational movements to facilitate the removal of excess powder from cavities. The vibration causes loose powder particles to move and exit through openings, significantly improving removal efficiency while maintaining operational simplicity
Solution Approach 2:
The system uses a controlled gas flow (pneumatic mechanism) to blow excess powder out of cavities through openings. This pneumatic approach automates the removal process, eliminating manual labor while maintaining process simplicity and improving productivity
2Productivity
If motors or electrical drives are used to shake out powder residues, then the removal efficiency is improved, but the risk of ignition and explosion increases
Solution Approach 1:
The patent replaces electrical motors and drives with a mechanically-driven vibration generator that operates without electrical components inside the powder-containing chamber. This substitution eliminates ignition sources while maintaining effective powder removal capability
Solution Approach 2:
The apparatus creates an inert or controlled atmosphere within the working chamber to prevent ignition of powder residues. By controlling the atmospheric environment and eliminating electrical ignition sources, the system safely achieves efficient powder removal
3Adaptability or versatility
If heavy components are processed, then the manufacturing capability is improved, but the difficulty of removing excess powder increases
Solution Approach 1:
The vibration generator produces vibrational movements that effectively loosen and remove excess powder from heavy components. The mechanical vibration overcomes the weight and complexity issues, enabling efficient powder removal from substantial turbine components
Solution Approach 2:
The pneumatic system delivers controlled gas flows that effectively blow powder from heavy components. The high-velocity gas streams overcome the mass and complexity of heavy parts, enabling thorough powder removal without manual handling difficulties
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 apparatus effectively removes excess powder from complex components while ensuring operational safety by preventing ignition sources within the working space, thus enabling the industrialization of additive manufacturing processes.
Implementation Method 1
an actuation means (3) for mechanically actuating the platform (1) during a removal of the excess material (P). Said actuation means (3) is preferably configured to actuate the base material at a broad frequency range or a plurality of frequencies or frequency ranges
Data Source
Figure 1~2
AI summary
An Apparatus (100) for removing excess material (P), preferably a powder, from a cavity (12) of a component (10) is provided. The apparatus comprises: - a platform (1) for retaining the component (10), preferably an additively manufactured component (10), - a drive mechanism (2) being coupled to the platform (1), wherein the drive mechanism (2) is configured to rotate the component (10) being retained by the platform (1) independently around two orthogonal spatial directions (X, Y) and each with an unlimited angular deflection (α,β), - an actuation means (3) for mechanically actuating the platform (1) during a removal of the excess material (P), and - a housing (4), defining a working space (WS) in which the excess material (P) can be removed the cavity (12), wherein the housing (4) seals the working space (WS) against an environment, and wherein any electrical components for the drive mechanism (2) are arranged out of the working space (WS). Further, a method of operating the apparatus is presented.