Spatter Removal in Additive Manufacturing Application Devices
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Solution Overview
Problem
The presence of spatters, or non-consolidated build material agglomerates, in additive manufacturing processes leads to inhomogeneities and compromises the quality of the consolidation of build material and the resulting three-dimensional objects, as they can have different chemical properties and be coarser than the initial material, making their removal challenging.
Innovation Solution
A build material application device equipped with both a build material application element and a spatter removal element, where the spatter removal element is designed to efficiently remove spatters from previously consolidated layers before fresh material is applied, allowing for a highly integrated and efficient removal process, with various spatter removal elements such as blades, brushes, blowing/sucking nozzles, and vibrational elements, and a supporting construction for mechanical coupling and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spatter removal is performed using separate dedicated equipment, then spatter removal effectiveness is improved, but device complexity and process integration increase
Solution Approach 1:
The patent combines the spatter removal function with the build material application device by integrating a spatter removal element into the existing application device structure. This merging approach allows spatter removal to be performed using the same equipment that applies build material, thereby improving spatter removal effectiveness while avoiding the need for separate dedicated equipment and maintaining device simplicity.
Solution Approach 2:
The build material application device is designed to perform multiple functions: applying build material and removing spatters. The spatter removal element is integrated into the application device, enabling it to serve both purposes. This multi-functionality resolves the contradiction by achieving effective spatter removal without increasing device complexity, as the same device structure is utilized for both operations.
2Manufacturing precision
If spatter removal is performed before material application, then build material layer quality is improved, but process time increases
Solution Approach 1:
The spatter removal element is positioned to remove spatters from the previously consolidated layer before fresh build material is applied. This preliminary action ensures that spatters are eliminated in advance of material application, improving build material layer quality. The integrated design allows this preliminary spatter removal to occur within the same operational cycle as material application, minimizing additional process time.
Solution Approach 2:
The patent enables continuous operation by integrating spatter removal and material application into a single coordinated process. The spatter removal element operates in conjunction with the material application element, allowing spatter removal to occur continuously as part of the layer formation process rather than as a separate discrete step. This continuity maintains high build material layer quality while avoiding significant increases in process time.
3Manufacturing precision
If multiple spatter removal elements are used, then spatter removal effectiveness is improved, but device complexity increases
Solution Approach 1:
The spatter removal function is divided into multiple spatter removal elements that can be integrated into the build material application device. Each element contributes to spatter removal from different areas or angles, improving overall spatter removal effectiveness. The segmented approach allows the functionality to be distributed across multiple components within the existing device structure, achieving enhanced performance without proportionally increasing device complexity.
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 integrated approach ensures a high-quality build material layer application by effectively removing spatters, thereby improving the consistency and quality of the additive manufacturing process and the final product.
Implementation Method 1
A build material application device equipped with both a build material application element and a spatter removal element, where the spatter removal element is designed to efficiently remove spatters from previously consolidated layers
Implementation Method 2
apparatus for additively manufacturing at least one three-dimensional object by means of successive layerwise selective irradiation and consolidation of layers of build material which can be consolidated by means of at least one energy beam
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Build material application device (5) for an apparatus (1) for additively manufacturing at least one three-dimensional object (2) by means of successive layerwise selective irradiation and consolidation of layers of build material (3) which can be consolidated by means of at least one energy beam (4), the build material application device (5) comprising: - at least one build material application element (8) configured to apply an amount of build material (3) in a build plane (E) of a respective apparatus (1) for additively manufacturing at least one three-dimensional object (2); - at least one spatter removal element (9) configured to remove spatters (10) present in a layer of build material (3) of a respective apparatus (1) for additively manufacturing a three-dimensional object (2), particularly to remove spatters (10) originating from a selective irradiation of the respective layer of build material (3).