3D Printing Sintering Process Abnormal Protrusion Removal
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Solution Overview
Problem
The existing methods for creating three-dimensional objects through laminating sintered layers often result in abnormal sintering protrusions due to scattered working scraps, which can stop the shaping process by interfering with the next powdery layer, especially when high-density objects with thin layers are produced.
Innovation Solution
A method and apparatus that form and laminate sintered layers while detecting and removing abnormally sintered portions using a blade load or optical detection, preventing process stops by ensuring only the detected protrusions are machined, and allowing for efficient removal within the sintered layer formation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an optical beam is irradiated on a powdery layer to form a sintered layer, then a three-dimensional object can be manufactured through laminating sintered layers, but abnormally sintered portions (protrusions) are produced due to scattered sparks and molten powder residue
Solution Approach 1:
The invention performs preliminary removal of abnormally sintered portions during the sintering process itself, before the next powdery layer is formed. The detection unit detects protrusions during sintering, and the removal unit immediately removes them, preventing them from affecting subsequent layers. This preliminary action eliminates the need for post-processing and enables continuous manufacturing.
Solution Approach 2:
The invention implements a feedback mechanism where the detection unit continuously monitors the sintered layer surface for abnormally sintered portions, and the control unit adjusts the removal unit's operation based on detection results. This closed-loop feedback system ensures that only detected protrusions are removed, maintaining surface quality while enabling continuous production.
2Productivity
If the surface of the sintered layer is not leveled, then the shaping process can continue without interruption, but working scraps and abnormally sintered portions protrude upward and cause process stops
Solution Approach 1:
The invention performs preliminary detection and removal of abnormally sintered portions during the sintering process, before they can protrude upward and cause process stops. By acting in advance, the system maintains both manufacturing continuity and process stability without requiring post-sintering leveling operations.
Solution Approach 2:
The invention enables the sintering process to self-correct by incorporating detection and removal capabilities within the sintering operation itself. The system serves its own quality control needs by automatically detecting and removing defects during formation, eliminating the need for separate leveling operations and maintaining continuous production.
3Manufacturing precision
If a leveling blade is used to level the surface of the powdery layer, then the surface can be flattened, but the blade may be brought into contact with abnormally sintered portions and stop the shaping process
Solution Approach 1:
The invention performs preliminary removal of abnormally sintered portions during the sintering process, before the leveling blade is needed. By removing protrusions in advance, the blade can proceed through the powdery layer without contact, maintaining both surface flatness and manufacturing continuity without process stops.
4Manufacturing precision
If abnormally sintered portions are removed after sintering, then the surface quality can be improved, but the shaping process must be stopped and time is lost
Solution Approach 1:
The invention performs preliminary removal of abnormally sintered portions during the sintering process itself, before the next powdery layer is formed. This eliminates the need for post-sintering removal operations, maintaining surface quality while avoiding process interruptions and time losses.
Solution Approach 2:
The invention maintains continuous useful action by integrating detection and removal operations within the sintering process flow. The removal unit operates continuously during sintering, and the detection unit monitors throughout, ensuring that defect removal does not interrupt the manufacturing process and that productivity is maintained while surface quality is improved.
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 prevents the shaping process from being halted by abnormal sintering protrusions, allowing for continuous production of high-density three-dimensional objects by accurately detecting and removing these issues, thus ensuring a smooth operation and maintaining the quality of the final product.
Implementation Method 1
irradiating an optical beam on a predetermined portion of a powdery layer to form a sintered layer
Implementation Method 2
irradiating an optical beam on a predetermined portion of a powdery layer to form a sintered layer
Data Source
AI summary
A three-dimensional object is made by repeating a process. An optical beam is irradiated on a predetermined portion of a powdery layer to form a sintered layer. A new powdery layer is formed on a surface of the sintered layer. An optical beam is irradiated on a predetermined portion of the new powdery layer to form a new sintered layer united with the underlying sintered layer. Because a portion of the sintered layer that is higher than a predetermined level is removed as occasion demands, the abnormally sintered portion on the sintered layer can be removed, making it possible to prevent stoppage of the shaping process, which may be caused by the abnormally sintered portion.