3D Printing Using Swarf Particles to Reduce Material Costs
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Solution Overview
Problem
Existing 3D printing techniques like DMLS and SLM require tightly controlled atmospheres and high-power lasers, leading to increased costs due to expensive powders and potential contamination risks.
Innovation Solution
A 3D printing apparatus using a stream of swarf particles deposited in a die cavity, comprising a plunger, vice, abrasive cutting wheel, and cutter spindle, which generates micro-sized particles that adhere to form multiple layers within a die, allowing for cost-effective and contamination-controlled 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If DMLS or SLM techniques are used for 3D printing, then high-power laser beam can facilitate adhesion of powder onto substrate, but tightly controlled atmosphere and expensive powder are required leading to increased cost
Solution Approach 1:
The patent uses inexpensive swarf particles (metal shavings) as the printing material instead of expensive specialized powders. These swarf particles are byproducts from machining operations, making them readily available and cost-effective for 3D printing applications.
Solution Approach 2:
The patent replaces the high-power laser beam system with a mechanical spray deposition system. The swarf particles are propelled onto the substrate using mechanical means (gas pressure or mechanical spray) rather than thermal laser sintering, eliminating the need for expensive laser equipment and tightly controlled atmospheric conditions.
2Strength
If DMLS or SLM techniques are used for 3D printing, then high-power laser beam can facilitate adhesion of powder onto substrate, but tightly controlled atmosphere is required to prevent contamination
Solution Approach 1:
The patent replaces the laser-based thermal process with a mechanical spray deposition process. This substitution eliminates the requirement for tightly controlled atmospheric conditions, vacuum systems, and sophisticated gas flow control mechanisms that are necessary for laser sintering processes.
Solution Approach 2:
By using swarf particles instead of specialized powders, the patent reduces the need for controlled atmosphere systems. The swarf particles are less sensitive to oxidation and contamination compared to fine metal powders, allowing the process to be performed in simpler environmental conditions.
3Strength
If expensive powder is used for 3D printing, then adhesion onto substrate can be achieved, but overall cost of 3D printing increases
Solution Approach 1:
The patent uses swarf particles - inexpensive metal shavings that are byproducts of machining operations - as the printing material. This replaces expensive specialized 3D printing powders while maintaining adequate adhesion properties through the mechanical spray deposition process.
Solution Approach 2:
The patent changes the physical state and delivery method of the material from fine powder to swarf particles. This parameter change allows the use of inexpensive materials while achieving effective deposition and adhesion through controlled particle velocity and impact energy in the spray process.
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 method enables sustainable, cost-effective 3D printing with dense bonding and varied material applications, including metals and polymers, while maintaining the shape of the die cavity, and can be performed in a controlled environment to prevent contamination.
Implementation Method 1
The abrasive cutting wheel may be used for cutting the workpiece to generate the stream of swarf particles
Data Source
AI summary
Disclosed is a technology being implemented in an apparatus for depositing multiple layers of a stream of swarf particles. The stream of swarf particles is generated by interfacing a cutting abrasive wheel on a workpiece. The generated stream of swarf particles may be directed towards a cavity of a die. Multiple layers of stream of swarf particles further results in a 3D printed object that takes the shape of the cavity of the die. The apparatus may also be used to coat substrates. Substrates may include but not limited to metal surfaces, polymers, and ceramics.