Vibrating Orifice for Additive Manufacturing Powder Control

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Solution Overview

Problem

Existing additive manufacturing systems face challenges in accurately depositing powder for each layer, leading to issues like shortfills, excess powder buildup, and errors in the build object due to inadequate powder control.

Innovation Solution

The system employs a recoater arm with a powder deposition system that includes a single orifice component with vibrational components, allowing for precise control of powder flow by vibrating the orifice component to establish a pathway for the powder, thereby improving the accuracy of powder deposition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a large volume of powder is provided for each layer, then shortfills are avoided, but excess powder builds up and causes errors

Engineering Contradiction:

Improvevolume of powderVSAvoidaccuracy of powder deposition

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent applies mechanical vibration to the orifice component to control powder flow. The vibrational component causes the orifice component to vibrate, which establishes a pathway for powder to pass through the orifices. This vibration mechanism enables precise control of powder deposition volume, allowing the system to deposit exactly the required amount without excess buildup or shortfills, thereby resolving the contradiction between providing sufficient powder and maintaining deposition accuracy.

Inventive Principle:

Principle #18Mechanical vibration

2Quantity of substance

If the orifice component has multiple openings, then powder flow is restricted, but it is difficult to control the exact volume deposited

Engineering Contradiction:

Improvevolume of powderVSAvoidcontrol of powder flow

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The vibrational component mechanically vibrates the orifice component at controlled frequencies and amplitudes. This vibration dynamically opens and closes the orifices, enabling precise control over the duration and rate of powder flow. By adjusting vibration parameters, the system can accurately control the volume of powder deposited through the multiple orifices, transforming a static restriction into a dynamically controllable flow mechanism.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The vibration of the orifice component creates periodic opening and closing of the powder flow pathways. This periodic action allows the system to control powder deposition in discrete, measurable increments. The controller can regulate the duty cycle, frequency, and amplitude of the vibration to precisely match the required powder volume for each layer, enabling accurate volume control through rhythmic, controllable flow cycles.

Inventive Principle:

Principle #19Periodic action

3Manufacturing precision

If powder is not accurately controlled, then deposition is simple, but errors occur in the build object

Engineering Contradiction:

Improveaccuracy of powder depositionVSAvoidcomplexity of powder control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The vibrational component provides a relatively simple mechanical solution to achieve precise powder control. By vibrating the orifice component, the system creates a reliable mechanism for controlling powder flow without requiring complex electronic valves, sensors, or feedback systems. The vibration-based control achieves accurate powder deposition through straightforward mechanical means, improving manufacturing precision while maintaining acceptable device complexity.

Inventive Principle:

Principle #18Mechanical vibration

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 enhances the controller's ability to accurately control the volume of powder deposited, reducing errors and improving the quality of the build object by minimizing shortfills and excess powder issues.

Implementation Method 1

a vibrational component operably coupled to the at least one orifice member, wherein operation of the vibrational component causes the at least one orifice member to vibrate and enter the second mode to allow the second amount of powder to flow through the one or more perforations

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentUS20250128327A1Vibrating mechanism for controlling powder dispensing in additive manufacturing systems, and related systems and methods

Publication Date: 2025.04.24 BLUE ORIGIN MANUFACTURING LLC

AI summary

Additive manufacturing systems and associated methods are disclosed herein. In some embodiments, the additive manufacturing system includes a build chamber that has an active build region, a support platform positioned in the active build region and movable in an upward direction, and a recoater arm positioned in the build chamber and movable in a first lateral direction above the active build region. The recoater arm can spread a powder over the active build region during a build process using first and second blades. The recoater arm can also include at least one orifice component positioned between the first and second blades to block a flow of the powder while the at least one orifice component is stationary and a vibrational component operably coupled to the at least one orifice component. The additive manufacturing system can also include a controller operably coupled to the vibrational component, to control operation of the vibrational component.