Selective Laser Sintering Powder Removal for Tool Protection
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Solution Overview
Problem
The selective laser sintering method results in a rough surface finish and tool chipping or breakage due to powder adherence, which complicates machining and affects surface smoothness.
Innovation Solution
A method involving a surface-machining process with a suction nozzle to remove powder around the solidified layer before machining, using a path aligned with the contours and regions defined by the machining tool's capabilities to minimize powder interference and stress on the tool and surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If selective laser sintering method is used to manufacture three-dimensional shaped object, then manufacturing efficiency and ability to produce complicated contour shapes are improved, but surface finish deteriorates (rough surface with Rz of several hundred micrometers)
Solution Approach 1:
The suction nozzle removes powder from the surface of the solidified layer before the machining process begins. This preliminary removal of powder prevents powder adhesion during subsequent machining operations, addressing the surface finish problem before it occurs while maintaining the efficient additive manufacturing process
2Manufacturing precision
If machining process is applied to the rough surface, then surface smoothness is improved, but tool chipping and breakage occur due to powder interference
Solution Approach 1:
The suction nozzle extracts and removes powder particles from the surface region before machining. By taking out the harmful powder that would otherwise interfere with the machining tool, the system prevents tool chipping and breakage while enabling the machining process to achieve smooth surfaces
Solution Approach 2:
The suction process applies a preliminary anti-action by removing powder that would cause harmful effects during machining. This preemptive removal prevents powder adhesion to the tool, eliminating the root cause of tool chipping and breakage before the machining operation begins
3Quantity of substance
If powder remains around the solidified layer, then material utilization is maintained, but powder adhesion causes surface roughness and machining difficulties
Solution Approach 1:
The suction nozzle selectively removes powder only from the surface region where it would interfere with machining, while leaving powder in other regions intact for potential reuse. This local removal approach maintains overall material utilization while eliminating powder adhesion problems in the critical machining zone
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 approach reduces tool chipping and breakage, improves surface smoothness by minimizing powder interference, and maintains efficient manufacturing time with a smoother surface finish.
Implementation Method 1
forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the predetermined portion of the powder or a melting and subsequent solidification thereof
Implementation Method 2
allowing a sintering of the predetermined portion of the powder
Implementation Method 3
a suction removal of the powder located around the solidified layer and/or the shaped object is performed by a suction nozzle
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
There is provided a selective laser sintering method capable of reducing the trouble in chipping or breakage of the machining tool and the like. The manufacturing method according to an embodiment of the present invention is a method for manufacturing a three-dimensional shaped object by repetition of a powder-layer forming and a solidified-layer forming, the repetition comprising the steps of (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof, and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein the method includes at least one step of a surface-machining process for machining a surface of the solidified layer and/or the shaped object by a machining tool at a point in time after the formation of the solidified layer and/or the manufacturing of the shaped object, wherein a suction removal of the powder located around the solidified layer and/or the shaped object is performed by a suction nozzle prior to the surface-machining process, such that the powder is locally removed in consideration of a lowermost machinable level of the machining tool, wherein the suction nozzle during the local removal of the powder is operated under such a condition that a movement path of the suction nozzle is a path along (a) a contour "A" of a cross section of the solidified layer positioned at the lowermost machinable level of the machining tool, (b) a contour "B" of an upper surface of the solidified layer formed most immediately before the suction removal, and (c) a region "C" obtained by subtracting a closed region "B' " from a closed region "A' ", the closed regions "A' " and "B' " being respectively obtained by a planar projection of the contours "A" and "B" with respect to the same plane, the planar projection being provided in a stacking direction of the solidified layers.