Suction Nozzle Cross-Section Optimization for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing devices face issues with inhomogeneous flow fields and inefficient removal of process by-products due to suboptimal design of suction and inlet nozzles, leading to flaws in the manufacturing process and components, particularly in selective laser beam melting.
Innovation Solution
The device incorporates suction and inlet nozzles with optimized fluid-dynamically relevant cross-sectional areas and contoured flow channels to enhance gas flow rates and homogeneity, reducing the cross-sectional areas of suction nozzles by up to 66% and achieving a 3-fold increase in flow rate, ensuring improved removal of process by-products and maintaining a clear high-energy beam path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the sum of fluid-dynamically relevant cross-sectional areas at suction nozzles is increased three times compared to inlet nozzles, then the flow rate at suction nozzle is improved, but the flow field becomes inhomogeneous and process by-products are not efficiently removed
Solution Approach 1:
The patent applies parameter changes by optimizing the ratio of cross-sectional areas between suction and inlet nozzles. Specifically, the sum of fluid-dynamically relevant cross-sectional areas at the entrances of suction nozzles is set to be between 0.3 to 2.5 times the sum of cross-sectional areas at the exits of inlet nozzles. This parameter optimization creates a balanced flow field that maintains high flow rates while ensuring homogeneous distribution for effective process by-product removal.
2Productivity
If the flow rate at suction nozzle is increased, then process by-products are removed more efficiently, but the flow field becomes inhomogeneous leading to deficient removal in certain regions
Solution Approach 1:
The patent resolves this contradiction by optimizing the cross-sectional area ratio parameter between suction and inlet nozzles to 0.3-2.5 times, which balances flow rate and homogeneity. Additionally, the suction nozzles are positioned at a distance of 0.5 to 2 times the construction chamber height above the component platform, and inlet nozzles are positioned 1 to 3 times the chamber height above, creating optimal flow patterns that ensure both high productivity and manufacturing precision.
Solution Approach 2:
The patent addresses flow field homogeneity by considering the vertical dimension in nozzle positioning. By setting specific height ratios (suction nozzle at 0.5-2x chamber height, inlet nozzle at 1-3x chamber height), the solution creates a three-dimensional flow optimization that ensures homogeneous process by-product removal across all regions of the construction chamber.
3Object-affected harmful factors
If process by-products are not efficiently removed, then smolder leads to defocusing and shielding of laser beam, but increasing suction nozzle cross-sectional area three times causes inhomogeneous flow
Solution Approach 1:
The patent eliminates laser beam shielding by optimizing the nozzle cross-sectional area ratio to 0.3-2.5 times and positioning nozzles at specific height ratios (suction: 0.5-2x chamber height, inlet: 1-3x chamber height). This parameter optimization ensures efficient process by-product removal that prevents smolder accumulation, thereby maintaining laser beam focus and preventing shielding effects throughout the construction chamber.
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 design results in a more homogeneous flow field, improved removal of process by-products, and enhanced quality of three-dimensional object manufacturing or repair by preventing beam shielding and ensuring proper bonding, making the process suitable for serial production.
Implementation Method 1
the inlet nozzle and the suction nozzle being arranged in such a way as to create a flow of gas that passes at least partially above a buildup and joining zone
Implementation Method 2
the component material is locally melted and/or sintered layer by layer by supplying at least one high-energy beam, such as an electron or laser beam
Implementation Method 3
local melting or sintering of the component material layer by layer through energy supplied in the region of the buildup and joining zone
Implementation Method 4
local melting or sintering of the component material layer by layer through energy supplied in the region of the buildup and joining zone
Data Source
AI summary
The invention relates to a device for the manufacture or repair of a three-dimensional object, comprising at least one construction chamber for a successive solidification of at least one solidifiable material layer by the layer in predefined regions for the layer-by-layer buildup of the three-dimensional object or for the layer-by-layer repair of individual regions of the three-dimensional object within the construction chamber, and at least one inlet nozzle and at least one suction nozzle for a process gas, wherein the inlet nozzle and the suction nozzle are arranged in such a way that a gas flow that passes at least partially over a construction platform formed in a construction chamber is created.