Additive Manufacturing Sleeve Transfer for Unloading
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Solution Overview
Problem
Current additive manufacturing machines by powder bed deposition face significant productivity losses due to the need for cooling manufactured parts and non-consolidated powder before unloading, which can take several hours and disrupt the inert atmosphere.
Innovation Solution
The proposed solution involves a machine with a horizontally arranged separating wall, allowing for the transfer of a manufacturing sleeve between an upper and lower chamber, enabling unloading without cooling, while maintaining powder-tightness and inert atmosphere integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sleeve is kept inside the enclosure and cannot be dismounted, then the inert atmosphere is maintained, but the unloading operation becomes complex and time-consuming
Solution Approach 1:
The enclosure is segmented into an upper chamber and a lower chamber by a separating wall. The sleeve can be positioned in either chamber independently, allowing the unloading operation to be simplified by transferring the sleeve to the upper chamber where it can be accessed, while the lower chamber maintains the inert atmosphere for ongoing manufacturing operations.
Solution Approach 2:
The separating wall acts as an intermediary structure that enables independent access to the sleeve without compromising the inert atmosphere. By providing a physical division between chambers, it allows the sleeve to be transferred and unloaded in the upper chamber while the lower chamber continues to maintain its sealed inert environment.
2Loss of time
If the manufacturing plate is displaced in the lower area of the machine, then the unloading can be performed before cooling, but the system becomes complex and difficult to implement
Solution Approach 1:
Instead of displacing the manufacturing plate vertically in the lower area, the solution transfers the entire sleeve horizontally between the lower chamber and upper chamber. This dimensional change from vertical plate displacement to horizontal sleeve transfer simplifies the actuator requirements while achieving the same goal of enabling unloading before cooling.
3Ease of operation
If the sleeve is transferred to the upper chamber for unloading, then the unloading operation is simplified, but the risk of introducing powder into difficult-to-clean areas increases
Solution Approach 1:
The enclosure is divided into two separate chambers with a separating wall. The lower chamber contains the manufacturing operations and potential powder, while the upper chamber is designated for unloading operations. This segmentation creates a physical barrier that prevents powder from the lower chamber from contaminating the unloading area in the upper chamber.
Solution Approach 2:
The separating wall serves as an intermediary barrier between the powder-containing lower chamber and the clean upper chamber. It allows the sleeve to be transferred between chambers while maintaining a clear separation that prevents powder contamination during the transfer and unloading operations.
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 allows for immediate unloading of manufactured parts and non-consolidated powder without waiting for cooling, thereby significantly reducing downtime and maintaining the inert atmosphere, thus enhancing productivity and operational efficiency.
Implementation Method 1
consolidation is carried out by melting using an energy source such as a laser beam or an electron beam
Implementation Method 2
consolidation is carried out by melting using an energy source such as a laser beam or an electron beam
Implementation Method 3
The manufacturing plate 47 slides along a vertical axis (Z) inside the manufacturing sleeve 400 under the effect of an actuator 31
Implementation Method 4
the transfer system being configured to transfer the manufacturing sleeve from the manufacturing position to the opening, and to transfer the manufacturing sleeve from the opening to the manufacturing position in the upper chamber
Data Source
AI summary
A machine for additive manufacturing by powder bed deposition comprises an enclosure (10) comprising a separating wall (23) arranged so as to separate an upper chamber (20) and a lower chamber (30), an actuator (31) disposed in the lower chamber, means for depositing a powdered material, and a consolidating device (80) for selectively consolidating each powder layer. The upper chamber comprises an opening (21) for the passage of a manufacturing sleeve having a manufacturing plate (47), and the machine comprises a transfer system (91) configured to transfer the manufacturing sleeve from a manufacturing position to the opening, the transfer system also being configured to transfer the manufacturing sleeve from the opening to the manufacturing position.