Stream Guiding Unit for Additive Manufacturing Gas Control

Solution Overview

Problem

Existing additively manufacturing apparatuses face challenges in controlling gas stream parameters, as high flow rates or velocities can blow away build material, while low rates fail to remove residues effectively, compromising process quality.

Innovation Solution

Incorporating a stream guiding unit within the application device to direct the gas stream along a defined path, preventing it from affecting build material and allowing for increased flow rates or velocities without disturbing the material, by positioning the stream guiding element to shield the build plane during irradiation and reduce flow rates during material application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If the streaming velocity or flow rate of the gas stream is chosen high to remove residues effectively, then residue removal is improved, but build material can be blown away causing uneven distribution and process termination

Engineering Contradiction:

Improveresidue removalVSAvoidbuild material distribution

Core Design Contradiction:

Object-generated harmful factorsVSManufacturing precision

Solution Approach 1:

The gas stream path is segmented into different zones using stream guiding elements. The process chamber is divided into a first region for material application and a second region for residue removal, allowing different gas flow conditions in each zone without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Stream guiding elements act as intermediaries between the gas stream source and the build material. These elements redirect the gas flow, preventing direct interaction between high-velocity gas and build material while maintaining effective residue removal capabilities

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the streaming velocity or flow rate of the gas stream is chosen low to preserve build material, then build material distribution is improved, but residues cannot be properly removed from the process chamber

Engineering Contradiction:

Improvebuild material distributionVSAvoidresidue accumulation

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The gas stream path is segmented into different zones using stream guiding elements. The process chamber is divided into a first region for material application and a second region for residue removal, allowing different gas flow conditions in each zone without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different gas flow characteristics are applied to different regions of the process chamber. The first region receives low-velocity gas to protect build material, while the second region receives high-velocity gas for effective residue removal, optimizing conditions locally for each function

Inventive Principle:

Principle #3Local quality

3Productivity

If the flow rate of the gas stream is increased to maintain inert atmosphere, then atmosphere control is improved, but additional build material is stirred up causing uneven layers

Engineering Contradiction:

Improveatmosphere control efficiencyVSAvoidbuild material layer uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The gas stream path is segmented into different zones using stream guiding elements. The process chamber is divided into a first region for material application and a second region for residue removal, allowing different gas flow conditions in each zone without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Stream guiding elements act as intermediaries between the gas stream source and the build material. These elements redirect the gas flow, preventing direct interaction between high-velocity gas and build material while maintaining effective residue removal capabilities

Inventive Principle:

Principle #24Intermediary (Mediator)

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 efficient removal of residues and improved distribution of build material, enhancing the quality of the additive manufacturing process by allowing higher gas stream parameters without negatively impacting the build material, thus preventing process termination and ensuring even layer formation.

Implementation Method 1

the stream guiding unit is adapted to guide the gas stream along a streaming path

Methodology Applied

Scientific EffectFluid flow guidance:

Data Source

PatentUS11084218B2Apparatus for additively manufacturing three-dimensional objects

Publication Date: 2021.08.10 CONCEPT LASER

AI summary

Apparatus (1) for additively manufacturing three-dimensional objects (2) by means of successive layerwise selective consolidation of layers of a build material (3) which can be consolidated by means of an energy source (4), which apparatus (1) comprises a stream generating device (6) adapted to generate a gas stream (7) in a process chamber (8) of the apparatus (1) and an application device (18) comprising an application unit (19) with an application element (20) that is moveable across a build plane (14) of the apparatus (1) for applying build material (3) in the build plane (14), wherein the application device (18) comprises at least one stream guiding unit (22) that is adapted to guide the gas stream (7) along a streaming path (26).