Segmented Additive Manufacturing Build Unit for Powder Adaptation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing installations for selective laser melting (SLM) and selective laser sintering (SLS) lack flexibility to easily change metallic powder composition between production cycles or adapt to different build scales efficiently, leading to inefficiencies and increased waste.
Innovation Solution
The installation features a unitary build device and a unitary dosing device that are mountable within an enclosure, allowing for easy adaptation between different build scales and powder compositions. These devices include electric drive motors for stepwise vertical adjustment, enabling efficient powder management and layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional SLM installations use fixed build chambers and powder supplies, then structural simplicity is maintained, but adaptability to different build scales and powder compositions is reduced
Solution Approach 1:
The build device is divided into separable components: a build chamber and a powder supply device. Each component can be independently removed and replaced, allowing the installation to be adapted to different build scales and powder compositions without redesigning the entire system. The build chamber can be detached from the support structure, and the powder supply device can be independently replaced.
Solution Approach 2:
The support structure is designed with universal mounting features that can accommodate different sizes and types of build chambers and powder supply devices. The electric drive system and control architecture are also designed to work with various configurations, enabling a single installation platform to serve multiple additive manufacturing applications.
2Ease of operation
If conventional installations require complete disassembly for maintenance or changes, then component accessibility is improved, but loss of time during production cycles increases
Solution Approach 1:
The build device is segmented into independently removable components that can be accessed and replaced without disassembling the entire installation. The build chamber can be lifted out from the support structure, and the powder supply device can be independently replaced, enabling rapid maintenance and changes during production cycles.
Solution Approach 2:
The build chamber and powder supply device are designed with pre-configured mounting interfaces and alignment features that enable quick attachment and detachment. The electric drive system is pre-wired with accessible connectors, allowing components to be replaced without complex reconfiguration or extensive disassembly.
3Adaptability or versatility
If conventional installations use fixed powder supply volumes, then device complexity is reduced, but adaptability to different component sizes is limited
Solution Approach 1:
The powder supply system is separated into an independent powder supply device that can be detached from the support structure. This allows the powder supply volume to be adjusted by replacing the entire powder supply device with one of appropriate size, rather than modifying a fixed integrated system. The build chamber volume can also be adjusted by replacing the build chamber component.
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 allows for flexible and efficient additive manufacturing by enabling easy changes in metallic powder composition and adapting to different build scales, thereby minimizing waste and optimizing powder usage.
Implementation Method 1
a laser beam radiation source (c) operable for applying a focused laser beam to successive layers of powder
Implementation Method 2
the heated area of each layer is rapidly solidified and fixed to the preceding layer below
Implementation Method 3
suitable for use in the manufacture of components are articles by selective laser sintering (SLS)
Implementation Method 4
a build lift table contained in the main build chamber and further including an electric drive build motor by which the build lift table is able to be adjusted vertically in a stepwise manner
Implementation Method 5
a dosing lift table contained in the dosing chamber and further including an electric drive dosing motor by which the dosing lift table is able to be adjusted vertically in a stepwise manner whereby successive quantities of metallic powder in the dosing chamber can be raised
Implementation Method 6
a re-coater device operable to form successive layers of metallic powder over an area of the upper surface containing the build area
Data Source
AI summary
An AM installation utilising SLM or SLS a chamber of a housing with a protective atmosphere, a support structure in the chamber defines an upper horizontal surface on which a laser source is operable for focusing onto predetermined regions of a build area of the plane of the horizontal surface. The laser beam source is operable so areas of each of successive layers of powder material are sintered or fully molten throughout its layer thickness. A dosing device raises successive quantities of powder to the level of the upper surface to enable a re-coater to form the layers. A separable build device unit defines build chamber opening at the upper surface, and includes a lift table and an electric drive by which the lift table is stepwise vertically adjustable so a progressively built component is lowerable into the build chamber.