3D Shaping Device Shroud Ventilation

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Solution Overview

Problem

In three-dimensional shaping devices, the inactive gas discharged to prevent fumes from lowering laser irradiation efficiency can blow up powder layers, leading to defects and reduced quality of the shaped object, especially when the inactive gas supply cover is gradually narrower.

Innovation Solution

A three-dimensional shaping device with a shroud having independent inside spaces and ventilation members, where inert gas is supplied and fumes are exhausted, preventing powder scattering by controlling air flow velocity parallel to the powder layer, and using mesh or porous ventilation members with varying openings and porosity to manage fume flow and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If inactive gas is discharged through the discharge port of the inactive gas supply cover to prevent fumes, then laser irradiation efficiency is maintained, but powder is blown up and quality of the shaped object deteriorates

Engineering Contradiction:

Improvelaser irradiation efficiencyVSAvoidquality of the shaped object

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The inactive gas supply cover is divided into a discharge port section and a narrow section, with the narrow section positioned downstream of the discharge port in the gas flow direction. This segmentation allows the gas to be discharged effectively at the discharge port while the subsequent narrow section prevents excessive gas velocity from blowing up the powder layer, thus resolving the contradiction between maintaining laser irradiation efficiency and preventing powder scattering.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The narrow section acts as an intermediary element between the discharge port and the shaping area. It serves to reduce the velocity of the discharged inactive gas before the gas reaches the powder layer, thereby preventing powder blow-up while still allowing the gas to perform its function of protecting the laser irradiation area from fumes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the inactive gas supply cover is formed to be gradually narrower towards the discharge port, then gas flow efficiency is improved, but powder scattering increases and defects occur

Engineering Contradiction:

Improvegas flow efficiencyVSAvoidquality of the shaped object

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The cover structure is segmented into distinct functional sections: a discharge port section for efficient gas discharge and a separate narrow section positioned downstream. This segmentation allows the narrow section to serve as a velocity-reducing zone that prevents powder scattering, while the discharge port section maintains gas flow efficiency. The key is that the narrow section is positioned after the discharge port in the gas flow direction, not before.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of making the cover narrower towards the discharge port (which increases gas velocity at the discharge point), the invention inverts the approach by placing the narrow section downstream of the discharge port. This reversal allows the gas to be discharged at full efficiency first, then gradually reduce velocity in the narrow section to prevent powder blow-up.

Inventive Principle:

Principle #13The other way round (Inversion)

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

Prevents powder scattering and defects, maintaining the quality of the shaped object by controlling air flow and fume management within the shroud, reducing the need for frequent maintenance of ventilation members.

Implementation Method 1

a laser irradiation unit configured to emit a laser light

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

so as to sinter or melt and solidify a powder that constitutes the powder layer

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

a first ventilation member made of a mesh or a porous body that partitions the first inside space and the inside space of the shroud, and by a second ventilation member made of a mesh or a porous body that partitions the inside space of the shroud and the second inside space

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11518091B2Three-dimensional shaping device

Publication Date: 2022.12.06 HONDA MOTOR CO LTD

AI summary

A three-dimensional shaping device includes a laser irradiation unit (10), a shroud (20), and a protection member (14). The laser irradiation unit includes an optical system (12). The shroud (20) includes an inside space (S0) that extends from one end opening portion (202) to another end opening portion (206). The protection member (14) is formed of a transparent material and is arranged at the one end opening portion (202) of the shroud (20) and causes a laser light emitted from the laser irradiation unit (10) to be transmitted therethrough so that a three-dimensional shaped object is fabricated in a shaping area by sintering or melting and solidifying a powder. The shroud (20) further includes a side wall portion (22) that demarcates a first inside space (S1) and a second inside space (S2), an air supply port (210), an exhaust port (220), and ventilation members (212, 214).