Variable Aperture Powder Dispensing for Additive Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In additive manufacturing, existing powder spreading methods using doctor blades or rollers result in inconsistent powder distribution, reduced packing density, and increased porosity due to streaks and craters, leading to higher production costs and longer cycle times.

Innovation Solution

An additive manufacturing system with a build plate and a powder dispensing unit featuring a base member with multiple recoater blades of varying spacings and angles, and a vibratory compaction system to ensure uniform powder distribution and increased packing density, using a powder dispensing aperture with variable size to match the part geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If powder is spread using a doctor blade or roller, then powder is deposited on the build plate, but the powder distribution becomes inconsistent and non-uniform with streaks and craters

Engineering Contradiction:

Improvepowder distribution uniformityVSAvoidpacking density consistency

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent replaces the mechanical doctor blade or roller spreading system with a vibratory compaction system. The vibratory system uses vibrations to compact and level the powder, eliminating the mechanical dragging action that causes streaks and craters, thereby achieving uniform powder distribution without the harmful effects of traditional mechanical spreading methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies mechanical vibration through a vibratory compaction system to achieve uniform powder distribution. The vibrations help to level and compact the powder particles consistently across the build plate, eliminating the streaks and craters produced by mechanical blade or roller methods while maintaining reliable packing density

Inventive Principle:

Principle #18Mechanical vibration

2Area of stationary object

If powder is spread over an area larger than the part being produced, then the build plate is fully covered, but extra powder must be reclaimed which increases production cycle time

Engineering Contradiction:

Improvepowder coverage areaVSAvoidproduction cycle time

Core Design Contradiction:

Area of stationary objectVSProductivity

Solution Approach 1:

The patent applies local quality by using a doctor blade or roller that spreads powder only in the specific areas where the part will be manufactured, rather than uniformly covering the entire build plate. This localized powder application eliminates the need to reclaim and reprocess large amounts of excess powder, thereby reducing production cycle time while maintaining adequate powder coverage where needed

Inventive Principle:

Principle #3Local quality

3Quantity of substance

If a roller is used to spread powder, then powder is distributed across the build plate, but powder particles stick to the roller creating craters

Engineering Contradiction:

Improvepowder distributionVSAvoidpowder bed uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent replaces the roller-based mechanical spreading system with a vibratory compaction system. This substitution eliminates the adhesion problem where powder particles stick to the roller surface, preventing crater formation while still achieving uniform powder distribution through vibration-based compaction and leveling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If the doctor blade or roller drags powder particles across the build plate, then powder is spread, but streaks are produced and packing density is reduced

Engineering Contradiction:

Improvepowder spreading capabilityVSAvoidpowder distribution quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the dragging mechanical action of doctor blades or rollers with a vibratory compaction system. The vibratory mechanism compacts and levels powder through vibrations rather than dragging, eliminating the formation of streaks and maintaining high packing density while preserving the ease of powder spreading operation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The system achieves consistent and dense powder distribution, reducing porosity and cycle times, and optimizing powder usage by dispensing the exact amount needed for the part geometry, thereby enhancing the manufacturing efficiency and reducing waste.

Implementation Method 1

a vibratory compaction system to ensure uniform powder distribution and increased packing density

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentUS10814555B2Powder dispensing unit, powder spreading unit, and a vibratory compaction system of an additive manufacturing system and methods therefor

Publication Date: 2020.10.27 THE BOEING CO

AI summary

An additive manufacturing system including a build plate, and at least one powder reservoir configured to store and deposit powder onto the build plate, the at least one powder reservoir including a powder dispensing aperture having a variable size. The powder dispensing unit includes a base member, and the least one powder reservoir coupled to the base member.