Temperature-Controlled Powder Distributor for Additive Manufacturing
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Solution Overview
Problem
In powder bed fusion additive manufacturing, uneven powder distribution leads to dimension instability and reduced mechanical properties in the final 3D article, and frequent smoothening processes increase manufacturing time and affect local temperature, requiring more power to maintain the process.
Innovation Solution
A temperature-controlled powder distributor with a support structure connected to a cooling/heating media supply outside the process chamber, allowing for precise temperature regulation and stable powder distribution, reducing the risk of powder sticking and mechanical issues due to temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple powder application and smoothening processes are performed to achieve even powder distribution, then powder layer quality is improved, but manufacturing time increases and local temperature stability deteriorates
Solution Approach 1:
The patent applies preliminary action by performing a single powder application with optimized distributor design and temperature control before the melting process, eliminating the need for multiple smoothening passes. The powder is distributed with controlled temperature and velocity to ensure even layers from the start.
2Manufacturing precision
If multiple powder application and smoothening processes are performed to achieve even powder distribution, then powder layer quality is improved, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by performing a single powder application with optimized distributor design and temperature control before the melting process, eliminating the need for multiple smoothening passes. The powder is distributed with controlled temperature and velocity to ensure even layers from the start.
3Device complexity
If powder distributor temperature is not controlled, then device complexity is reduced, but powder distribution accuracy deteriorates and powder sticking occurs
Solution Approach 1:
The patent applies parameter changes by actively controlling the temperature of the powder distributor to maintain optimal conditions for powder flow and distribution. The temperature is regulated to prevent powder sticking while ensuring uniform distribution across the build area.
4Ease of operation
If powder distributor temperature varies, then device operation is simpler, but mechanical stability deteriorates due to expansion and contraction
Solution Approach 1:
The patent applies parameter changes by actively controlling the temperature of the powder distributor to maintain optimal conditions for powder flow and distribution. The temperature is regulated to prevent powder sticking while ensuring uniform distribution across the build area.
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 a more accurate and efficient additive manufacturing process with improved powder distribution stability, reduced risk of powder sticking, and enhanced mechanical properties of the final product, while maintaining a consistent temperature for the powder distributor.
Implementation Method 1
at least one support structure for supporting the powder distributor is connectable to a cooling/heating media supply outside the process chamber and the support structure is adapted for transporting the cooling/heating media to and from the powder distributor
Implementation Method 2
a temperature controlled powder distributor may be better controlled with respect to temperature variating mechanical issues such as expansion and/or contraction due to different temperatures of the powder distributor in different occasions
Data Source
AI summary
Provided is an additive manufacturing apparatus for additive manufacturing of three dimensional objects by selectively solidifying a powder material layer by layer in a process chamber, wherein the apparatus comprises a powder distributor movable across a build area of a build tank for applying a layer of powder material thereon and a solidification device for selectively solidifying the applied powder layer at positions corresponding to a cross section of the object to be manufactured and a control unit adapted to repeat the steps of applying and selectively solidifying until the object is completed, wherein at least one support structure for supporting the powder distributor and/or a bellows assembly associated there-with is connectable to a cooling/heating media supply outside the process chamber and the support structure and/or the bellows assembly is adapted for transporting the cooling/heating media to and from the powder distributor. Certain embodiments further or alternatively include a bellows assembly connected or connectable to a cooling/heating media supply positioned outside the process chamber, the bellows assembly being configured for transporting the cooling/heating media to and from the powder distributor.