Shielded Suction Nozzle for Powder Bed Ejection Removal
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Solution Overview
Problem
Current waste product removal systems in additive manufacturing are inadequate in addressing deposition products such as oxidized particles and vaporized metal, which can cause defects and suboptimal material properties in final parts.
Innovation Solution
A waste product removal system comprising a suction nozzle with a shield to prevent reintroduction of material, a sweep gas outlet manifold, and a motive system that positions and orients the nozzle to effectively capture and remove deposition products during the additive manufacturing process, including a gantry and controller for precise movement and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional waste product removal methods are used, then the system is simple, but deposition products are not adequately removed causing defects in final parts
Solution Approach 1:
The waste product removal system is segmented into distinct functional components: a suction nozzle for capturing deposition products, a shield for directing material flow, a sweep gas outlet manifold for gas flow control, and a motive system for positioning. This segmentation allows each component to be optimized for its specific function while working together to achieve effective waste product removal and improved part quality
Solution Approach 2:
A shield is introduced as an intermediary component between the build area and the suction nozzle. The shield extends downward near the nozzle to guide material ejection toward the suction source and prevent reintroduction of deposited material into the powder bed, thereby mediating the interaction between waste products and the build environment
2Productivity
If a shield is positioned close to the build area to prevent reintroduction of material, then material capture efficiency improves, but the risk of interfering with the manufacturing process increases
Solution Approach 1:
The shield is configured with specific dimensional parameters (positioned above the build area by less than about 5 mm, preferably about 1 mm) to dynamically balance its function of capturing waste products with the need to avoid interfering with the laser processing and powder bed stability, allowing efficient removal while maintaining process reliability
3Measurement precision
If a motive system is added to position and orient the suction nozzle, then waste product capture precision improves, but system complexity and cost increase
Solution Approach 1:
The motive system is designed to perform multiple functions: positioning the suction nozzle in two dimensions over the build area, orienting the nozzle for optimal capture angles, and coordinating with the laser gantry or powder recoater movements. This multi-functionality achieves precise waste product removal while minimizing the need for separate specialized components
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 efficiently removes hot and cold ejection products, reducing defects in final parts and enabling improved material properties by effectively capturing deposition products before they reintroduce into the powder bed, thus enhancing the quality of additive manufactured components.
Implementation Method 1
a suction nozzle configured to connect to a suction source for providing suction to a build area of the additive manufacturing system
Implementation Method 2
The shield can be configured to guide material ejection from the build area to the suction nozzle
Implementation Method 3
a sweep gas outlet manifold configured to be connected to a flow source
Data Source
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AI summary
A waste product removal system (100) for an additive manufacturing system (99) can include a suction nozzle (101) configured to connect to a suction source (103) for providing suction to a build area (105) of the additive manufacturing system (99). The waste product removal system (100) can include a shield (107) in operable communication with the nozzle (101) and configured to extend downward near the nozzle (101) to prevent reintroduction of the material ejection to a powder in the build area (105). The shield (107) can be configured to guide material ejection from the build area (105) to the suction nozzle (101).