Spacer Flow Guide for Additive Manufacturing Exhaust
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Solution Overview
Problem
In Direct Laser Sintering (DLS) and Direct Laser Melting (DLM) systems, smoke and particulate matter accumulation within the manufacturing chamber interferes with the laser beam, reducing its intensity and incorporating unwanted material into the object, leading to increased operating costs due to the need for large gas flow volumes to remove these particles.
Innovation Solution
An additive manufacturing system employing a spacer flow guide within the chamber to direct gas flows through main and bypass exhaust channels, reducing the chamber's gas volume and enabling a lower gas flow rate for effective particulate removal without compromising manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large gas flow volume is used to remove smoke and particulate matter from the chamber, then the quality of the resulting object is improved, but the operating costs and material costs increase
Solution Approach 1:
The chamber is divided into multiple zones using a partition wall with a perforated plate, creating a first chamber volume for laser processing and a second chamber volume for gas flow and particulate removal. This segmentation allows targeted gas flow where needed while reducing the total volume requiring expensive gas replacement.
Solution Approach 2:
Gas flow and particulate removal are concentrated in the second chamber volume rather than being applied uniformly throughout the entire chamber. The perforated plate directs gas flow locally to where particulates are generated, improving removal efficiency while reducing overall gas consumption.
2Object-generated harmful factors
If a large gas flow volume is used to remove smoke and particulate matter, then particulate removal effectiveness is improved, but the device complexity increases due to downstream reconditioning requirements
Solution Approach 1:
The partition wall with perforated plate extracts and isolates the gas flow and particulate removal function into a dedicated second chamber volume. This separates the harmful particulate generation zone from the laser processing zone, allowing targeted removal without requiring complex downstream reconditioning of the entire chamber atmosphere.
3Adaptability or versatility
If the chamber volume is made large to accommodate DLS/DLM system components, then the manufacturing capability is improved, but the gas flow rate required for particulate removal increases
Solution Approach 1:
The chamber is segmented into two functional volumes, allowing the first chamber volume to be sized for manufacturing capability while the second chamber volume is optimized for gas flow efficiency. This enables large-scale manufacturing without proportionally increasing the gas flow rate required for particulate removal.
4Productivity
If gas flow is directed through a large-volume chamber, then the manufacturing capacity is maintained, but the operating costs increase
Solution Approach 1:
Gas flow is concentrated in the second chamber volume where it is most effective for particulate removal, rather than being distributed uniformly throughout the entire chamber. This local concentration maintains manufacturing capacity while reducing overall gas consumption and operating costs.
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
The system effectively reduces recirculation and turbulence, allowing for efficient removal of particulates with a reduced gas flow rate, thereby lowering operating costs and improving the quality of the produced objects.
Implementation Method 1
a gas flow is introduced into the chamber to flow along the build platform in an effort to remove the smoke and/or particulate matter
Implementation Method 2
a focused energy source (e.g., an electron beam, a laser beam) to sinter or melt a powder material deposited on a build platform within a chamber
Implementation Method 3
selectively directing a laser beam onto a controlled amount of powder (e.g., a powder bed) on a substrate, so as to form a layer of fused particles
Implementation Method 4
Direct Laser Melting (DLM)... uses an energy beam to sinter or melt a fine powder
Implementation Method 5
The spacer flow guide is disposed within a downstream portion of the chamber... effectively reduces recirculation and turbulence
Data Source
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AI summary
The present disclosure relates to the manufacture and use of an additive manufacturing (AM) system (10) that employs a spacer flow guide (140) disposed or formed within a housing (30) that defines a chamber (32) of the AM system (10). The spacer flow guide (140) may direct various portions of a gas flow (252, 262) within the chamber (32) to respective exhaust channels (220, 224). For example, in combination with portions of the housing (30), the spacer flow guide (140) may define a main exhaust channel (220) that extends between the chamber (32) and a gas outlet (290) formed in a downstream end (204) of the housing (30). Additionally, a bypass exhaust channel (224) may be defined between the chamber (32) and a back surface (176) of the spacer flow guide (140) to fluidly couple an upper portion (244) of the chamber (32) to the main exhaust channel (220).