Techniques for Effective Gas Removal from 3D Printer Chambers

An additive manufacturing system that uses gas flow to remove smoke and particles from the chamber during manufacturing, improving the quality of printed objects. The system has an upper gas flow along the build platform and a lower gas flow directed parallel to the platform. The lower gas is introduced above or below the platform and guided by a contoured surface to flow parallel to the platform surface. This gas flow configuration prevents recirculation and efficiently removes smoke and particles from the chamber.

A gas extraction system for a 3D printing apparatus that allows precise control of the temperature and airflow in the printing chamber. The system uses a primary conduit with a primary inlet, interfacing inlet, and outlet. A secondary conduit connects the primary conduit to the working space inlet. Flow control devices regulate the flow of gas from the working space into the secondary conduit, which is then suctioned out by an external extraction source. This allows precise control of the temperature and airflow in the printing chamber while removing fumes and byproducts.

Automated optimization of evacuation gas flow (EGF) in additive manufacturing (AM) build chambers to improve component quality. The method involves receiving input parameters like chamber geometry and operating conditions, simulating gas flow in the modified chamber, extracting evacuation streamlines, and calculating flow improvements using a metric. This iterative process resolves an optimal chamber design with maximized EGF.

A fume extraction system for 3D printers that allows printing at high temperatures without releasing noxious fumes. A pump pulls air from the printer chamber through a filter to remove particulates and fumes. The filtered air is returned to the chamber. The filter contains an adsorption filter to remove noxious fumes. The system can operate in different modes during printing to maintain chamber pressure and temperature.

A fume extraction system for large-scale additive manufacturing machines that prevents contamination between work zones when using multiple energy beams to consolidate the powder. The system uses fixed-side manifolds and a movable central manifold above the overlap zone between adjacent work zones. The central manifold extends over the full transverse dimension and can translate longitudinally to cover the entire work surface. This allows fume extraction close to the powder without beams crossing work zones.

Reducing the amount of process gas wasted during additive manufacturing by collecting and reusing fluid displaced from the process chamber. The fluid is collected and/or fed back into the chamber or into another apparatus's chamber based on its process gas content. The collected fluid can be purified to increase the process gas content.

An additive manufacturing apparatus with a gas recirculation loop purifies the inert cover gas used during the process. The loop removes impurities from the cover gas to generate a clean cover gas that can be reintroduced into the chamber for the additive manufacturing process. The loop includes purification devices like particle filters and gas scrubbers to remove solid and gaseous impurities.

Gas delivery and purging device for additive manufacturing chamber to reduce purge times and gas volume by allowing a gas like argon to flow into the chamber in a non-turbulent, laminar manner that displaces other gases and forces them out. The device uses flexible tubes with pores across their entire surface area.

Regulating pressure within a three-dimensional printer to maintain consistent quality of printed parts. The pressure within the printer can fluctuate due to variations in the extraction rate of an external gas extraction system. An apparatus is installed in the printer that measures the pressure and compares it to a predetermined value. If the pressure is too low, the apparatus opens apertures in the printer to allow ambient air to flow into the extraction system. This stabilizes the pressure and maintains consistent part quality.

Additive manufacturing process chamber housing that improves powder bed fusion process efficiency by increasing gas flow rate without depleting the powder bed. The housing has a gas inlet and outlet to provide inert gas flow through the process chamber. The inlet and outlet are at opposite sides of the process chamber. The bottom has a support opening for a movable support. The gas inlet and outlet are configured to provide a gas flow in a main flow direction over the support opening. The housing has a door panel that can be closed to block access to the process chamber.

An additive manufacturing process that uses a movable gas exchange manifold system with the recoater mechanism to provide controlled gas exchange during the recoat cycle between print cycles. The manifold moves with the recoater over the powder bed to remove contaminated gas and add clean gas. This prevents accumulation of soot and other contaminants that can affect print quality.

Apparatus for additive manufacturing that allows precise control of the gas stream used in the process. The apparatus includes a gas processing device that determines the composition of the gas stream and guides it to either a purification device or back to the process chamber based on the determined composition. This allows adjusting the gas composition to optimize the additive manufacturing process for the specific build material being used.

Large-scale additive manufacturing machine with multiple gas flow systems to perform various functions like electronics cooling, condensate evacuation, and component cleaning with purge air. Each gas flow system has a dedicated circulation loop for circulating gas to the specific subsystem. This allows for more versatile and efficient gas flow compared to a single gas loop system.

Additive manufacturing systems that maintain consistent conditions within the print chamber to improve 3D object properties. The system uses multiple fans and sensors to control gas pressure and flow rate in the print chamber. The fans maintain the desired pressure and flow rate while sensors monitor the conditions. This allows the system to compensate for variations in suction or external conditions to maintain consistent conditions inside the print chamber.

A safe way to change filter elements in additive manufacturing machines that contain explosive or volatile particles. The filter assembly has a housing with a gas inlet and outlet for filtering contaminated gas. The housing has a removable filter element that can be replaced. The housing has a fluid inlet for adding a neutralizing fluid like water to neutralize the particles. The fluid inlet is sealed when the gas inlet and outlet are closed to prevent explosions. The fluid can be pumped in and out of the housing to neutralize the particles. The housing can be removed from the machine for replacement.

Selective solidification 3D printer that improves print quality by controlling gas flow to remove contaminants from the build area. The printer has switchable gas nozzles at the edge of the build area that can be toggled between suctioning gas from the chamber and a functionless state. The nozzles are controlled based on the printer's operating state to suction away fumes, particles and residues without disturbing the object being printed.

A mobile additive manufacturing installation with a self-supporting frame and a main manufacturing housing that can be transported by road. The installation has a main additive manufacturing machine inside the housing, a main inerting device to supply the machine with inert gas and capture fumes, and a main airlock for operator entry/exit. The inerting device filters fumes and manages gas pressure to prevent leakage. The main treatment device regulates temperature, humidity, and oxygen levels in the housing.

An additive manufacturing apparatus that captures fumes generated during the additive manufacturing process. The apparatus includes a mechanism that can move between the beam source and build stage to capture fumes generated when the powder is melted. This prevents fumes from escaping into the chamber or contaminating the powder supply. The capturing mechanism has a plate-like capture surface to maximize fume collection.

Additive manufacturing apparatus that allows for faster and more efficient inertization of the process chamber without requiring a large volume of inert gas to be circulated throughout the chamber. The apparatus uses a suction device that locally sucks process gas from the chamber and guides it out via a slit-like opening. This allows for targeted inertization of the build plane without requiring the entire chamber to be inertized.

Additive manufacturing apparatus for building parts by selectively consolidating flowable material in a layer-by-layer process. The apparatus has a build chamber, a module for providing a focussed energy beam, a gas flow circuit for generating a gas flow through the build chamber, and a pair of filter assemblies arranged in parallel within the gas flow circuit. The filter assemblies have valves that can be switched to connect the filter assembly in line with the gas flow. The apparatus also has a monitoring device and a controller that switch the filter assembly based on gas flow properties. This allows filter replacement during a build without interrupting the gas flow.