WO2021250560A1

WO2021250560A1 - A nested print-bed system for powder-based additive manufacturing process

Info

Publication number: WO2021250560A1
Application number: PCT/IB2021/055018
Authority: WO
Inventors: Vidyashankar C; Parivarthan REDDY B
Original assignee: Vidyashankar C; Reddy B Parivarthan
Priority date: 2020-06-08
Filing date: 2021-06-08
Publication date: 2021-12-16

Abstract

Present disclosure discloses a nested print-bed system (100) for powder-based additive manufacturing process. The system (100) includes a first print-bed (101) and a second print-bed (102), which include a first work-platform (103) and a second work-platform (104) respectively, which are movably supported by at least one actuator (112). The second work-platform (104) is structured to displace from a top position to at least one intermediate position, and the second work-platform (104) along with the first work-platform (103) are structured to displace from the top position to at least one intermediate position to define a second work volume (113) and a first work volume (111), respectively, where the first work volume (111) is larger than the second work volume (113). The configuration of the system (100) facilitates in defining work volume of different sizes for printing components of different sizes, with optimum utilization of the powder and, thus minimizing manufacturing cost.

Description

A NESTED PRINT-BED SYSTEM FOR POWDER-BASED ADDITIVE

MANUFACTURING PROCESS

The following specification particularly describes the invention and the manner in which it is to be performed. TECHNICAL FIELD

Present disclosure, in general, relates to a field of additive manufacturing. Particularly, but not exclusively, the present disclosure discloses a print-bed system for powder-based additive manufacturing process. Further, embodiments of the disclosure disclose a nested print-bed system for the powder-based additive manufacturing process, such as a selective laser sintering process.

BACKGROUND

Selective laser sintering process is a powder-based additive manufacturing process. Usually in the selective laser sintering process, powder of a requisite material type such as, but not limited to nylon powder, is used for producing articles of desired shape and configuration. In the process, powder is laid out on a printing bed using a layering mechanism. Upon laying the powder on the printing bed, laser is focused onto the laid powder for selectively sintering of the powder in a specific pre-defined pattern. Further, several layers of powder are laid and sintered in the specific pre-defined pattern. Upon selectively sintering the multiple layers of powder at specific pre-defined pattern, a final printed part or article is obtained.

In the conventional selective laser sintering process, size of the printing bed is fixed and thus, the work volume of the printing bed is also fixed. During sintering process, the powder is laid in the entire work volume of the printing bed layer by layer, irrespective of the size and number of components to be printed. This may lead to substantial wastage of powder, particularly during printing of small or lesser number of components, as large amount of loose powder (non-sintered) may be left over on the printing bed. Though, the unused powder can be extracted and reused, reusability of such powder is limited to 30-50%, and utilizing the reused powder would have an effect on mechanical properties of the final printed product, thus affecting quality of the final printing component. Further, as the amount of reusability of powder is less, it leads to substantial increase in the cost of the sintering process, which is undesired. In addition, as the entire work volume is used during the sintering process, the number of powder re-fillings cycles into a hopper, which lay powder in layers onto the printing bed are also more. The present disclosure is intended to overcome the above stated limitations.

SUMMARY

One or more shortcomings of the conventional print-bed system for powder-based additive manufacturing process, and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure, a nested print-bed system for powder based additive manufacturing process is disclosed. The system includes a first print- bed, which includes a first work-platform, movably supported on a base. Further, the system includes a second print-bed, which includes a second work-platform, supported on the base. The second print-bed is movably disposed within the first print-bed. The second work-platform is structured to independently displace from a top position to at least one intermediate position to define a second work volume and, the first work-platform is structured to displace along with the second work- platform from the top position to the at least one intermediate position to define a first work volume, which is greater than the second work volume.

In an embodiment, the first print-bed comprises a first body-portion supported on the base, the first body-portion is structured to enclose the first work-platform and the second print-bed.

In an embodiment, the first work-platform is structured to displace along with the second print- bed from the top position to the at least one intermediate position to define the first work volume.

In an embodiment, the second print-bed comprises a second body -portion, movably supported on the base, the second body -portion is structured to selectively divide the first work-platform and the second work-platform.

In an embodiment, the second work-platform is structured to displace between the top position and the at least one intermediate position within the second body -portion to vary the capacity of the second work volume. In an embodiment, the first work-platform is defined with a cavity to receive the second work- platform.

In an embodiment, the first work-platform and the second work-platform are supported by at least one actuator for displacing the first work-platform and the second work -platform between the top position and the at least one intermediate positions.

In an embodiment, the at least one actuator is one of a liner actuator and a rotary actuator.

In an embodiment, the system includes a sealing arrangement positioned between each of the first work-platform and the first body-portion, and the second work-platform and the second body-portion.

In an embodiment, the system includes one or more heating elements integrated with the first work-platform and the second work-platform, for heating the powder during additive manufacturing process.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following description.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

The novel features and characteristic of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings.

One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which: Figure. 1 illustrates a sectional view of a nested print-bed system, in accordance with an embodiment of the present disclosure.

Figure. 2 illustrates the sectional view of the nested print-bed system with a second work- platform of a second print-bed displaced from a top-position, in accordance with an embodiment of the present disclosure.

Figures. 3 and 4 illustrates the sectional view of the nested print-bed system with a first work- platform and the second work-platform displaced in tandem from the top-position, in accordance with an embodiment of the present disclosure.

Figure. 5 illustrates the sectional view of the nested print -bed system with the first work- platform displaced to an intermediate position and the second work-platform displaced beyond the first work-platform to define both first work volume and second work volume, in accordance with an embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

It is to be noted that a person skilled in the art would be motivated from the present disclosure and modify configuration of the nested print-bed system for powder-based additive manufacturing process. However, such modifications should be construed within the scope of the instant disclosure. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusions, such that a system, that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device, or mechanism. In other words, one or more elements in a system or an assembly preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the device or the system or the mechanism.

In the following description of the embodiments of the disclosure, reference is made to the accompanying figures that form a part hereof, and in which are shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that, changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

Figure. 1 is an exemplary embodiment of the present disclosure, which illustrates a sectional view of a nested print-bed system (100) [hereinafter interchangeably used as system] for carrying out powder-based additive manufacturing process. As an example, the powder-based additive manufacturing process may be, but not limited to a selective laser sintering process. The nested print-bed system (100) may broadly include a base (110), a first print-bed (101) and a second print-bed (102). The first print-bed (101) and the second print-bed (102) may be supported on the base (110), where the second print-bed (102) may be movably or despicably supported on the base (110). As apparent from Figure. 1, the second print-bed (102) may be movably disposed within the first print-bed (101), such that the second print-bed (102) may displace vertically within the first print-bed (101) between a top position and at least one intermediate position of a plurality of intermediate positions. As an example, the second print- bed (102) may be concentrically disposed within the first print-bed (101). In an embodiment, the second print-bed (102) may be positioned at a substantially central portion of the first print- bed (101).

Further, referring to Figure. 1 the second print-bed (102) may include a second body-portion (108), which may be movably supported on the base (110), and a second work-platform (104) which may movably supported on the base (110) and enclosed within the second body-portion (108). The second work-platform (104) may be configured to independently displace from a top position to at least one intermediate position of the plurality of intermediate positions, to define a second work volume (113) for carrying out additive-manufacturing process. Further, as apparent from Figure. 1, the first print-bed (101) may include a first body-portion (105), which may be fixedly supported on the base (110) and, a first work-platform (103) which may be movably supported on the base (110) and enclosed within the first body-portion (105). The first work-platform (103) may be configured to displace along with the second platform [thus, the second print-bed (102)] from the top position to the at least one intermediate position of the plurality of intermediate positions, to define a first work volume (111), which is greater than the second work volume (113), to carry out additive-manufacturing process. In an illustrated embodiment, each of the first body-portion (105) and the second body-portion (108) may include a plurality of walls defining, a substantially hollow rectangular configuration. However, the same should not be construed as a limitation as the first body-portion (105) and the second body-portion (108) may be defined with any geometrical shapes such as but not limiting to cylindrical, circular, square and the like.

The term “top position” may be inferred as position of the first work -platform (103) and the second work-platform (104) at brim of the first body-portion (105) and the second body- portion (108) and the term “intermediate position” may be inferred as any position within the first body-portion (105) and the second body-portion (108), below the top position.

In an embodiment, the second body -portion (108) may be structured to selectively divide the first work-platform (103) and the second work-platform (104), to define the second work volume (113). Further, as seen in Figure. 1, the first work-platform (103), the second work-platform (104) and the second print-bed (102) may be movably supported on the base (110) through at least one actuator (112). That is, the first work-platform (103) and the second work-platform (104) [thus, the second print-bed (102)] may be vertically displacable between the top position and the at least one intermediate position by the at least one actuator (112). In an embodiment, the at least one actuator (112) may be but not limiting to a rotary-linear actuator and a linear actuator. In an embodiment, the rotary-linear actuator may a lead screw/ball screw, which may be coupled with the rotatory actuator. As an example, the rotary actuator may be, but not limiting to an electric motor and the linear actuator may be but not limiting to a hydraulic actuator and a pneumatic actuator. In an illustrated embodiment, the first work-platform (103), the second work-platform (104) and the second print-bed (102) are supported by a pair of actuators and corresponding supporting columns or shafts. However, the same should not be construed as a limitation as the first work-platform (103), the second work-platform (104) and the second print-bed (102) may be supported by more than a pair of actuators based on the requirement.

In an embodiment, the second work-platform (104) may be configured to displace independent to the first work-platform (103), and the first work-platform (103) may be configured to displace in tandem with the second work-platform (104) [thus, the second print-bed (102)], based on the requirement.

Now referring to Figure. 2, which illustrates the sectional- view of the nested print-bed system (100) with the second print-bed (102) being displaced from the top position. In an embodiment, based on the requirement of the printing area, i.e., for printing smaller components, the second print-bed (102) may be displaced from the top position (as seen in Figure. 1) to at least one intermediate position of the plurality of intermediate positions. As apparent from Figure. 2, the at least one actuator (112) associated with the second work-platform (104) may be operated to displace the second work-platform (104) from the top-position to at least one the intermediate position, within the second body-portion (108). As an example, the second work- platform (104) may slide vertically downwards from the top position in engagement with the plurality of walls of the second print-bed (102). This displacement of the second work-platform (104) from the top-position may define the second work volume (113) within the second body- portion (108) [thus, the second print-bed (102)], for carrying out additive-manufacturing process [i.e., sintering process]. In an embodiment, the second work volume (113) defined, as a result of displacement of the second work-platform (104) within the second body-portion (108) of the second print-bed (102), may be substantially small and, thus aids in sintering of smaller components with optimum utilization of the powder, unlike conventional systems.

Turning now to Figure. 3, which illustrates the sectional-view of the nested print-bed system (100) with the first work-platform (103) and the second print-bed (102) [thus, the second work- platform (104)] displaced from the top position to at least one intermediate position. In an embodiment, based on the requirement of the printing area, i.e., substantially larger print-area for printing larger components, both the first work-platform (103) and the second print-bed

(102) may be displaced from the top position (as seen in Figure. 1) to at least one intermediate position (as seen in Figure. 3). As apparent from Figure. 3, the second work-platform (104) is received by the cavity defined in the first work-platform (103), and thus, forming the first work-platform (103), which may be relatively larger than the second work-platform (104), alone. Upon forming the common work-platform [i.e., combination of the first work-platform

(103) and the second work-platform (104)], the at least one actuator (112) may be operated such that the first work-platform (103) and the second print-bed (102) are displaced in tandem, from the top position. This displacement of the first work-platform (103) and the second print- bed (102) may define the first work volume (111) within the first body -portion (105) of the first print-bed (101), for carrying-out the sintering process. In an embodiment, the first work volume (111) defined due to displacement of the first work-platform (103) and the second print-bed (102) may be substantially larger than the second work volume (113) defined due to displacement of the second work-platform (104) alone, thus aids in sintering larger components.

Turning now to Figure. 4, the first work-platform (103) and the second print-bed (102) may be structured to further displace between the top position and at the at least one intermediate positions of the plurality of intermediate positions to vary capacity of the first work volume (111) during sintering process, such that components of larger lengths may be printed. Likewise, the second work-platform (104) may individually displace between the top position to at least one intermediate position of the plurality of intermediate positions to vary the capacity of the second work volume (113).

Referring now to Figure. 5, the first work-platform (103) and the second work-platform (102) may be structured such that, the second work-platform (102) may displace beyond the position of the first work-platform (103), thus facilitating in defining both first work volume (111) and the second work volume (113). As apparent from Figure. 5, the first work-platform (103) and the second print-bed (102) may displace in tandem to one of the intermediate position within the first body-portion (105). Further, the second work-platform (104) may displace beyond the intermediate position [i.e., the position where the first work-platform (103) and the second print-bed (102) are displaced to], to one of the intermediate position within the second body- portion (108). This configuration thus, aids in defining both the first work-volume (111) and the second work-volume (113) simultaneously.

In an embodiment, the nested print-bed system (100) including the first print-bed (101) and the second print-bed (102) is an exemplary embodiment and, the same cannot be construed as limitations, since the print-bed system (100) may include a plurality of print-beds, based on the requirement.

In an embodiment, the nested print-bed system (100) may include a sealing arrangement [not shown in figures] positioned between the first work-platform (103) and the plurality of walls of the first body-portion (105), and the second work-platform (104) and the plurality of walls of the second body-portion (108). The sealing arrangement is configured to prevent powder leakage through crevice between the work-platforms and the plurality of walls, during sintering process.

In an embodiment, the nested print-bed system (100) includes one or more heating elements integrated with the first work-platform (103) and the second work-platform (104) for heating the powder during sintering process.

In an embodiment, configuration of the nested print-bed system (100) aids in optimizing the utilization of powder, based on the components to be printed and, thus aids in reducing cost of printing process. In an embodiment, the configuration of the nested print-bed system (100) facilitates in better print quality due to better laser focusing during sintering process.

In an embodiment, the at least one actuator (112) may be associated with a control unit, which may be stored with preset instructions. Upon receiving signal or a trigger, the control unit may activate the at least one actuator (112) for displacing the second work-platform (104) to define second work volume ( 113 ) or both the second work-platform (104) and the first work-platform (103) in tandem to define the first work volume (111), based on the requirement.

In an embodiment, printing process on the smaller print-bed is faster, which results in faster manufacturing rate, unlike the conventional techniques which adapts larger work-platform even for printing smaller components.

Equivalents:

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.” While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims.

Referral numerals:

Claims

We Claim:

1. A nested print-bed system (100) for powder based additive manufacturing process, the system (100) comprising: a first print-bed (101) comprising a first work-platform (103), movably supported on a base (110); and a second print-bed (102) comprising a second work-platform (104), movably supported on the base (110), the second print-bed (102) is movably disposed within the first print-bed (101); wherein, the second work-platform (104) is structured to independently displace from a top position to at least one intermediate position to define a second work volume (113); wherein, the first work-platform (103) is structured to displace along with the second work-platform (104) from the top position to the at least one intermediate position to define a first work volume (111), greater than the second work volume (113).

2. The system (100) as claimed in claim 1, wherein the first print-bed (101) comprises a first body-portion (105) supported on the base (110), the first body-portion (105) is structured to enclose the first work-platform (103) and the second print-bed (102).

3. The system (100) as claimed in claim 1, wherein the first work-platform (103) is structured to displace along with the second print-bed (102) from the top position to the at least one intermediate position to define the first work volume (111).

4. The system (100) as claimed in claim 1, wherein the first work-platform (103) and the second print-bed (102) are structured to displace between the top position and the at least one intermediate position within the first body -portion (105) to vary capacity of the first work volume (111).

5. The system (100) as claimed in claim 1, wherein the second print-bed (102) comprises a second body-portion (108) movably supported on the base (110), the second body- portion (108) is structured to selectively divide the first work-platform (103) and the second work-platform (104).

6. The system (100) as claimed in claim 1, wherein the second work-platform (104) is structured to displace between the top position and the at least one intermediate position within the second body -portion (108) to vary the capacity of the second work volume

(113).

7. The system (100) as claimed in claim 1, wherein the second work-platform (104) is structured to displace beyond at least one intermediate position to which the first work- platform (103) is displaced such that, both the first work volume (111) and the second work volume (113) is defined.

8. The system (100) as claimed in claim 1, wherein the first work-platform (103) is defined with a cavity to receive the second work-platform (104).

9. The system (100) as claimed in claim 1, wherein the first work-platform (103) and the second work-platform (104) are supported by at least one actuator (112) for displacing the first work-platform (103) and the second work-platform (104) between the top position and the at least one intermediate positions.

10. The system (100) as claimed in claim 9, wherein the actuator (112) is at least one of liner actuator and rotary-linear actuator.

11. The system (100) as claimed in claim 1, comprises a sealing arrangement positioned between each of the first work-platform (103) and the first body-portion (105), and the second work-platform (104) and the second body -portion (108).

12. The system (100) as claimed in claim 1, comprises one or more heating elements integrated with the first work-platform (103) and the second work-platform (104), for heating a powder during additive manufacturing process.