Selective Laser Melting Gradient Material Apparatus

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Solution Overview

Problem

The selective laser melting/sintering technique lacks the capability to achieve continuous proportional change of powder composition and orderly layering of multiple phases, limiting its effectiveness in producing functionally gradient materials with complex shapes and large sizes, and is prone to powder oxidation and operator exposure.

Innovation Solution

An apparatus with a powder storer having multiple triangular partitions for gradient mixing, a rotational powder mixer, and a scraping plate, allowing for continuous proportional change of material composition through controlled powder mixing and laser melting, enabling horizontal gradient change direction perpendicular to the powder laying direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If traditional layer-by-layer powder replacement method is used, then functionally gradient materials can be produced, but the composition change is discontinuous and powder oxidation occurs

Engineering Contradiction:

Improvecomposition continuityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

The patent changes the fundamental parameter of powder delivery from discrete layer-by-layer replacement to continuous proportional mixing. The powder mixing device combines multiple powder sources with adjustable ratios, enabling continuous composition variation within each layer while maintaining manufacturing efficiency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention implements continuous powder mixing and delivery system where multiple powders are mixed in real-time at controlled proportions. This eliminates the discontinuous stopping and replacing operations of traditional methods, achieving both composition continuity and high productivity through uninterrupted manufacturing.

Inventive Principle:

Principle #20Continuity of useful action

2Shape

If selective laser melting is used with traditional powder laying, then complex shapes can be manufactured, but multiple phases cannot be orderly layered

Engineering Contradiction:

Improvecomplex shape capabilityVSAvoidpowder laying complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent segments the powder delivery system into multiple independent powder sources, each feeding a specific phase or material. This segmentation allows orderly control of different phases through the mixing device while maintaining the simplicity of the laser melting process for complex shape fabrication.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If layer-by-layer powder replacement is performed, then material composition can be changed, but powder oxidation and operator exposure occur

Engineering Contradiction:

Improvematerial composition flexibilityVSAvoidpowder oxidation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent implements an inert or protective atmosphere environment within the manufacturing chamber to prevent powder oxidation. The closed powder mixing and delivery system operates in this controlled atmosphere, eliminating exposure to oxygen while maintaining full compositional flexibility through the multi-powder mixing mechanism.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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

Enables the production of functionally gradient materials with stable, continuously varying mix ratios, supporting the processing of large-size parts with complex shapes and maintaining layer stability, overcoming the limitations of traditional layer-by-layer powder replacement methods.

Implementation Method 1

laser scanning array lens... melting the layer of powder by scanning with a laser beam

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

selective laser melting technique... melting the layer of powder by scanning with a laser beam

Methodology Applied

Scientific EffectSelective laser melting:

Data Source

PatentUS11618085B2Apparatus and method based on selective laser melting technique for preparing functionally gradient material

Publication Date: 2023.04.04 UNIV OF SCI & TECH BEIJING

AI summary

A selective laser melting technology-based apparatus for preparing a gradient material, comprising a laser scanning array lens, and a powder storer, a powder mixer, a powder scraping plate, and a working platform that are provided in sequence from top to bottom; the powder storer is provided with two or more partitions; a bottom portion of the powder storer is provided with an outlet; the powder mixer is provided under the powder storer and is a horizontally provided rotational mixer; the powder scraping plate is disposed under the powder mixer; the working platform is provided under the powder scraping plate; the laser scanning array lens is provided on the working platform. The present invention further relates to a method for preparing a gradient material, comprising powder storing, powder scraping, powder mixing, powder laying, and printing. The method can guarantee the two-phase powder ratio in each layer of powder not change.