Transparent Support Element for Powder Bed Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques using lasers for metal processing are costly, require complex safety measures, generate significant waste, and are time-consuming due to the need for complex powder bed cleaning and limited spatial melting areas.
Innovation Solution
A device that uses a light source with a transparent support element to melt granules from the top down, reducing waste and material usage by focusing light behind the granule layer, allowing for efficient handling and precise control of the melting process, and enabling the production of larger areas simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser is used for melting powder in additive manufacturing, then melting precision is achieved, but device cost and safety complexity increase
Solution Approach 1:
The patent replaces the laser system with a mechanical pressing system. A press applies mechanical force directly to the powder layer, compacting and fusing the particles through pressure rather than thermal energy. This substitution eliminates the complex safety infrastructure required for high-power lasers while achieving sufficient bonding for many applications.
Solution Approach 2:
The patent employs a simple, inexpensive pressing mechanism that can be rapidly repositioned or replaced. Rather than investing in expensive, maintenance-intensive laser systems, the solution uses affordable mechanical components that achieve the necessary function without requiring elaborate safety measures or complex control systems.
2Productivity
If laser melting is used from bottom to top, then workpiece is built layer by layer, but powder cleaning complexity and waste increase
Solution Approach 1:
The patent inverts the traditional build direction by pressing from the top surface downward through the powder layer. The press applies force from above, compacting the powder and fusing particles as it moves down. This top-down approach allows unused powder to remain on the surface for easy removal and reuse, dramatically reducing waste compared to bottom-up methods where powder must be carefully cleaned from completed surfaces.
Solution Approach 2:
The top-down pressing method enables straightforward recovery and reuse of unconsolidated powder. After each pressing cycle, the press can be lifted and the loose powder removed and reused in the next layer, minimizing material waste and reducing the complexity of powder management systems.
3Manufacturing precision
If small spatial area is melted by laser, then precise control is achieved, but production time increases
Solution Approach 1:
The pressing system divides the build area into multiple zones that can be pressed sequentially or simultaneously. By segmenting the workspace and using multiple pressing points or a distributed press array, the system processes larger areas in parallel, reducing overall production time while maintaining precise control over each local region through independent actuation of pressing elements.
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 approach significantly reduces resource consumption and costs, accelerates the manufacturing process by an order of magnitude, and minimizes waste, while ensuring precise control over the melting process and material adhesion, resulting in higher productivity and improved workpiece quality.
Implementation Method 1
a light source for emitting light in an operating state of the device... the beam path of the light is such that the light strikes the carrier element from the underside... in order to be able to melt a layer of the granulate spaced from the upper side of the carrier element with the light
Implementation Method 2
at least one focusing means which is configured to focus the light in the first direction behind the upper side of the carrier element
Implementation Method 3
a carrier element which is transparent to the light from the light source... the beam path of the light is such that the light strikes the carrier element from the underside with at least one directional component parallel to a first direction, which points from an underside of the carrier element opposite the upper side to the upper side
Implementation Method 4
the carrier element and/or the workpiece holder is/are movable by means of at least one displacement means with at least one directional component parallel and antiparallel to the first direction
Data Source
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AI summary
Apparatus (1) for the additive manufacture of at least one workpiece (2), comprising at least one light source (3) for emitting light (4) in an operating state, comprising a support element (6), which is transmissive to the light and, in the operating state, is arranged substantially horizontally such that meltable granules (9) can be arranged on an upper side (7) of the support element, wherein, in the operating state, the path of rays of the light is such that the light impinges on the support element from the underside with at least one directional component parallel to a first direction (10), which extends from an underside (8), opposite from the upper side, of the support element to the upper side, also comprising a workpiece holder (11), which is arranged behind the upper side, as seen in the first direction, wherein the support element and/or the workpiece holder can be moved by at least one displacement means (12) with at least one directional component parallel and antiparallel to the first direction, and also comprising at least one focusing means (5), which is designed to focus the light behind the upper side, as seen in the first direction.