Stabilized Build Platform for Large-Scale Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing systems face limitations in building large parts due to weight constraints of the powder bed and difficulty in controlling the build platform for uniform layer formation, which restricts the size and precision of objects that can be manufactured.
Innovation Solution
A stabilized build platform with a movable build unit and a powder dispenser, along with a recoater blade, is used to manage the powder distribution and bonding process, allowing for precise control and larger scale additive manufacturing by isolating the build platform from environmental vibrations and using a dynamically defined build envelope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the powder bed size is increased to manufacture larger parts, then the build volume is improved, but the weight of the powder bed increases making it difficult to control the build platform
Solution Approach 1:
The system divides the traditional single large powder bed into multiple smaller powder dispensing zones. The build platform remains relatively light while powder is selectively deposited only where needed, rather than requiring a large powder bed to cover the entire build volume.
Solution Approach 2:
The system transitions from a static powder bed configuration to a dynamic powder dispensing approach. The powder dispenser can move and deposit powder layer by layer only in the required areas, adapting the powder distribution to the current build stage and reducing the effective powder bed weight.
2Length of stationary object
If the build platform is made larger to accommodate bigger parts, then the part size capability is improved, but the precision of platform control and layer uniformity deteriorates
Solution Approach 1:
The build process is segmented into multiple passes with the powder dispenser visiting different zones sequentially. This allows each local area to receive precise powder deposition similar to smaller conventional systems, maintaining layer uniformity even for large build volumes.
Solution Approach 2:
The powder dispenser acts as an intermediary between the build platform and the final powder bed structure. It enables precise local powder deposition without requiring the entire large platform to be uniformly covered with powder, thus maintaining precision while enabling large builds.
3Device complexity
If conventional powder bed systems are used for large parts, then the system simplicity is maintained, but the maximum part size is limited by powder bed weight constraints
Solution Approach 1:
The system replaces the static large powder bed with a dynamic powder dispensing mechanism. This allows the effective build volume to expand beyond what a static powder bed of manageable weight could provide, while keeping the actual powder present on the platform limited to what is needed for the current layer.
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 solution enables the creation of high-precision, large-scale additively manufactured objects by maintaining precise control over the build platform and powder distribution, overcoming the size limitations of conventional systems and improving the quality of the manufactured parts.
Implementation Method 1
an irradiation emission directing device that directs an energy beam, for example, an electron beam or a laser beam, to sinter or melt a powder material
Implementation Method 2
melting entails fully melting particles of a powder to form a solid homogeneous mass
Implementation Method 3
The build platform may be stabilized and/or isolated from vibrations and other movements in the environment on which it is mounted
Data Source
AI summary
An additive manufacturing apparatus is provided. The additive manufacturing apparatus may include a stabilizing system; a build platform on the stabilizing system; and a build unit positioned over the build platform, wherein the build unit comprises a powder dispenser and a recoater blade. Methods are also provided for making an object from powder.