Powder Distribution in Selective Laser Sintering

Additive manufacturing device with powder recycling and paving capabilities to reduce powder usage and costs while optimizing large part forming. The device combines a scraper spreading system, powder feeding, and extrusion system inside the build chamber. It also has an atmosphere control system to maintain an inert gas environment. The scraper spreads a thin layer of powder, the feeder adds more powder, and the extruder precisely deposits powder for forming. This allows recycling and reuse of most powder, minimizing waste compared to layered filling or partial filling methods. The internal paving system also reduces powder requirements compared to external spreading.

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3D printing system that accurately controls the amount of powder output during additive manufacturing. It uses a load sensor beneath the build platform to measure the weight of the printed parts in real-time. A data processing unit receives the weight data from the sensor and sends it to the control center. The center adjusts the powder feed rate from the coaxial feeder based on the weight data to match the printing speed. This prevents overfeeding or underfeeding of powder compared to the melting rate.

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Real-time control of powder flow during laser cladding additive manufacturing to improve deposition efficiency and processing quality. The device allows dynamic adjustment of powder flow rate during the process to compensate for variations and optimize deposition. It uses a separate flow control module that can be independently rotated to change the leakage area in the powder channel. This allows real-time regulation of powder flow without affecting the motion of the feeding head or bin.

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A powder distribution system for 3D printing multi-material parts using selective laser sintering (SLS) technology. The system enables simultaneous deposition of different powder materials in each layer to create parts with internal features made of different materials. The system has a powder distribution module with a moving cylinder that can access and suction powder from multiple storage funnels above the build chamber. The cylinder can also rotate and translate horizontally to distribute powder over the build platform. This allows selective powder deposition without contaminating previously printed areas. An electrostatic gun with longitudinal motion can also be positioned precisely to sinter specific areas. This allows multi-material printing without the need for powder cleaning and recycling between layers.

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Improving metal additive manufacturing using laser powder-bed fusion to address challenges like low throughput, part defects, and damage to the laser system. The method involves generating and directing multiple laser beams to melt powdered metal in a selective manner. Monitoring the powder bed during melting allows adjusting the laser generation and focusing to optimize melting uniformity and prevent issues like spatter and excessive vaporization.

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High-precision powder spreading method for 3D printing to improve part quality and efficiency by accurately controlling the amount of powder spread based on the cross-sectional area of the part at each layer. This prevents issues like lack of powder leading to non-fusion defects or excessive powder consumption. The method involves measuring the cross-sectional area of the part at each layer and calculating the optimal powder spreading amount. This is done using computer vision and analysis of the part geometry. The calculated powder amount is then dispensed to precisely fill the area needed for sintering without excess powder. This provides consistent and stable part quality with reduced printing time and material waste compared to fixed or manual powder spreading.

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Additive manufacturing process and device to improve powder consumption efficiency in 3D printing by optimizing powder layer deposition. The process involves iteratively building the component layer by layer using a laser to sinter the powder. After each layer, a sensor checks if the right amount of powder was used. If too much or too little, the next layer is adjusted accordingly to compensate. This adaptive powder control reduces waste by avoiding overfilling or underfilling layers.

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Laser additive manufacturing system that enables real-time adjustment and online weighing of multiple powders to improve additive efficiency. The system has a powder supply unit, weighing unit, mixing unit, and control system. The powders are supplied by gravity, weighed individually, and mixed in real-time. The control system stops powder supply when weight reaches a set value, and coordinates mixing. This allows accurate, adjustable powder ratios for additive manufacturing.

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Feeding and spreading device for a laser 3D printer that improves powder spreading uniformity and quality for better 3D printing. The device has a triangular powder spreading part with a scraper and pressing plate to level the powder on the build platform. A powder lowering mechanism removes excess powder between layers. This prevents uneven powder thickness and improves printing quality.

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A loading system for 3D printers that reduces mounding and increases the uniformity of powder layers. The system has a loading chamber positioned over the supply container. Powder is dispensed into the chamber and compacted to increase uniformity. The chamber floor is then lowered into the supply container, transferring the compacted powder. This loading process helps distribute the powder more evenly throughout the container than directly filling it.

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Layer-by-layer powder spreading and compaction method and device for selective laser sintering that enables consistent and precise powder spreading and compacting for 3D printing. The method involves using a movable platform to spread powder on the build plate, then lowering a pressing plate to compact it. The build plate moves up to compress the powder between it and the pressing plate. This provides evenly compacted layers for SLM printing without pore generation or dimensional errors. The platform returns to the powder supply cylinder and the pressing plate covers it to complete a cycle.

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A powder feeding mechanism for 3D printing gradient materials using powder bed fusion. The mechanism has multiple powder quantifiers, mixers, vibration heads, and a flattening mechanism. The quantifiers deliver powder to the mixers in proportion to the required gradient composition for each layer. The mixed powder is then vibrated onto the bed at the correct positions. The flattening mechanism levels the powder between layers. This allows separate powder feeds with different compositions to be mixed and deposited in the correct sequence to create gradient layers.

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Additive manufacturing using a powder bed with powder distributed on a build surface includes a nozzle configured to direct and control the flow of gas over the powder bed. The nozzle may include a peripheral duct wall defining a channel with an inlet and an outlet. The channel directs the flow. The duct wall may diverge from the inlet to the outlet of the duct wall to slow the velocity of the gas flow. A number of vanes are distributed across the channel and may be configured as symmetric airfoils to reduce turbulence of the flow. A number of guides extend between the vanes. Each guide is disposed at an angle tuned to direct the gas over the powder bed without blowing the deposited powder off the build surface.

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A 3D printer that removes powder build-up from the powder dispensing system to maintain uniform layer thickness. The printer has a vibrating powder coater that scans over the build plate and dispenses powder for each layer. After a set number of layers, the coater is moved to an overflow chamber and vibrated to shake off the accumulated powder. This prevents excess powder from affecting subsequent layers. The printer uses a controller to automate the powder removal process.

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Improved recoating and dust collection systems for powder-based 3D printers that enable more efficient and controlled 3D printing using fine powders. The recoating system uses ultrasonic vibrations applied to a perforated screen to dispense the powder in uniform layers. This prevents the pluming of the fine powder particles during dispensing. The dust collection system captures any powder particles that become airborne during printing to prevent contamination and loss of material. The combination of the recoater and dust collection systems allows fine powders to be used with powder-based 3D printers without issues like pluming and excess powder.

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Powder delivery mechanism for 3D printers that uses a rotating doser with a recess to move a consistent amount of powder from a hopper to a trough for each layer.

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A powder feeding device for laser cladding that enables gradient powder feeding for better quality and efficiency. The device has a rotating powder mixing bin connected to a motor inside the cover. The bin contains rotating blades that mix the powder as it is fed. This ensures uniform powder composition by breaking up clumps and distributing particles. The mixed powder then flows into the cladding chamber through holes in the cover.

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Intelligent powder spreading method for laser selective melting additive manufacturing to improve powder bed quality and prevent defects like splashing and collapse. The method involves using an electromagnetic generator to induce a Lorentz force on the powder particles during spreading. This increases particle adhesion and reduces splashing. A high-speed camera monitors the spreading angle and regulates parameters to optimize quality. Collected splash particles are processed by the electromagnetic generator to prevent contamination of the printing chamber.

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A powder mixing device for laser cladding that improves powder homogeneity and allows efficient adjustment of alloy compositions. The device has multiple powder feeding structures, a stirrer, and a mixer with protrusions on the top surface. Powders from different sources are fed into the stirrer to pre-mix. This pre-mixed powder then goes into the mixer where protrusions collide with the powder to further disperse and mix it. This sequential mixing process ensures uniform composition across the powder fed to the laser cladding system.

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Powder supply device for selective laser sintering that reduces powder waste and dust compared to conventional systems. The device has a reciprocating powder spreading car that has a pressing plate to compact powder into a falling bin. A bellows feeds powder into the car. A sieving cylinder and sieve separate and collect fine powder. The spoke motor spreads the compacted powder layer by layer. This enables selective sintering with less excess and waste powder compared to directly supplying excess powder from an upper bin. The compaction and sieving steps minimize fine powder generation.

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Powder supply device for additive manufacturing of a drop-and-drop laser array to improve efficiency and reduce waste in powder bed fusion (PBF) 3D printing. The device uses a falling powder feeding mechanism instead of a spreader. Powder is supplied to the printing chamber through vertical pipes with gaps between them. The powder falls freely into the chamber where it is spread by a unit below. This allows excess powder from the previous layer to fall into the next layer, increasing powder utilization and reducing waste compared to spreading more powder overall. It also eliminates the need to empty the chamber between prints since the powder falls into the next layer.

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A small batch powder dropping device for additive manufacturing systems like selective laser melting (SLM) machines that improves powder utilization, reduces waste, simplifies powder changing, and allows easier material switching. The device has a movable powder storage unit with a quantitative bin that can hold smaller amounts of powder compared to the main hopper. This allows precise and repeatable powder dispensing for small builds without wasting excess powder. The quantitative bin is removable for easy powder replacement. The device also has a counterweight system to stabilize it and a limiting pin to accurately align with the SLM powder spreader.

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Device for preparing gradient materials using 3D printing techniques. The device allows customized gradient materials to be created by selectively depositing and solidifying powders of different compositions on a rotating substrate. It uses a movable powder spreader to distribute powder layers with varying compositions onto the substrate. A laser scanner solidifies the powders to create the gradient structure.

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Laser additive manufacturing system with multiple powder feeders to improve component composition uniformity when additively manufacturing composite materials. The system uses a laser with a laser processing head and a powder feeder with multiple powder tanks containing different materials. During additive manufacturing, the powder feeders are controlled based on the component's additive strategy to converge the powder flows at the same point on the substrate. This allows the powders to mix more evenly due to their own impact forces, avoiding segregation issues from long-distance transport. The different materials in the tanks provide more uniform component distribution in the final composite part.

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Directional powder feeding system for additive manufacturing of diamond tools using laser melting. The system enables controlled arrangement of diamond and metal powder for forming high-quality diamond tools with low internal stress. It uses a powder feeding device with a linear motion feeder and powder spreading mechanism that precisely deposits the powder in a predetermined direction. This allows directional control of the powder arrangement, preventing overlaps and voids that can cause stress concentrations and defects during laser melting. The feeding device is integrated into a laser selective melting machine for manufacturing diamond tools with improved strength and density.

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Multifunctional laser cladding powder feeder for additive manufacturing that allows dry powder feeding, powder mixing, and real-time powder level monitoring to improve laser cladding quality and efficiency. The feeder has a powder tube with a level sensor, a mixing bin with stirring and heating, and multiple powder inlets from separate containers. This enables adjusting powder composition, mixing, and drying. A controller, alarms, and sensors monitor powder levels and temperature.

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A powder feeding system for laser cladding that improves powder distribution accuracy and impurity filtration for high-speed cladding processes. The system uses a guide tube with a regular pyramid inside to evenly distribute the powder from the tube into a separation cavity. The powder then flows through two channels to exit the cavity and feed the cladding process. This ensures precise powder separation and uniformity. Additionally, a separate powder filter module is added to remove impurities from the powder before it enters the cladding process.

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Upper powder feeding system for selective laser melting (SLM) 3D printers that enables multi-material printing. The system has dual powder storage tanks and inclined powder drop tubes to feed separate materials into the SLM build chamber. The powder tanks are side by side and the drop tubes have parallel bottoms angled away from each other. This allows simultaneous powder feeding from both tanks into the printer's powder spreader for layered manufacturing of composite parts using different materials.

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A selective laser melting (SLM) powder feeding and spreading system for multi-powder composite 3D printing that enables efficient and controlled powder handling for printing complex metal parts with different powder types. The system uses automated powder feeding and blank area filling mechanisms to simplify powder management during multi-material printing. The feeding mechanism moves the spreading seat horizontally and longitudinally to selectively pick up powder from hoppers. A baffle with staggered holes prevents powder leakage. The spreading seat moves vertically with a telescopic cylinder to fill blank areas as layers increase. This avoids centralized powder recovery and separation issues. The system also has a hexagonal plank and column configuration to form a stable layer plane.

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Laser sintering 3D printer with improved sealing, cleaning, powder spreading, and efficiency. The printer has a retractable forming cylinder that seals the build chamber and allows cleaning by integrating the build plate. The powder supply uses a spiral structure to distribute powder evenly. The scraper has a dynamic leveler and resistance wire to prevent powder bridging. The build cylinder lifts and lowers using a telescoping mechanism.

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A quantitative powder feeding device for selective laser sintering (SLS) printers that allows accurate and consistent powder delivery during the 3D printing process. The device uses a vertical powder feed mechanism with a rotating axis that connects to the powder supply motor. The feed bin has a separate powder separation tube, buffer, and dropping port. This allows the powder to be guided and dispensed in a controlled manner into the SLS build chamber. This prevents powder bridging and ensures consistent layer coverage compared to traditional powder spreading methods.

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Powder feeding device for selective laser melting and digital material forming that allows multi-material 3D printing with high accuracy and material composition control. The device has a weighing and proportioning system to quantitatively supply multiple powder materials with adjustable ratios. It also has fixed-point conveying to accurately deliver the specified material to a preset position on the forming surface. This enables independent powder feeding mechanisms for both powder laying and powder feeding of materials in fixed points and areas. The integrated system improves powder utilization, flexibility, and applicability of multiple materials for additive manufacturing.

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A continuous gradient material powder spreading device for additive manufacturing that allows producing parts with gradual composition transitions between materials. The device uses an inclined baffle in the powder replenishment bin to divide it into multiple triangular sections. Each section has a different material composition. A scraper moves along the sections to spread the powder, mixing and blending the compositions for a smooth gradient. This enables producing parts with gradual composition transitions between materials using selective laser melting (SLM) additive manufacturing.

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Relay powder feeding device for large-format laser selective melting equipment to overcome challenges of powder feeding for large-size parts. The device has a flexible telescoping hose that moves with the forming system. A motion compensation device reduces hose fluctuation during powder reciprocation to prevent bending and powder spillage. A powder shunting mechanism inside the hopper stabilizes powder levels. Monitoring the hopper powder quantity ensures consistent feeding.

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Selective laser sintering (SLS) 3D printing system with upper and lower powder supply and powder recycling for improved material utilization. The system has separate upper and lower powder supply boxes that can contain different powders. This allows mixed powder feeding from top to bottom. The upper and lower powder boxes are lifted and lowered to supply powders to the build platform. The system also recycles unused powder from each layer by separating and returning it to the appropriate supply box. This prevents powder waste and enables printing parts with different powder types.

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Upper powder supply and bidirectional powder spreading device for selective laser sintering (SLS) 3D printers that allows bi-directional powder spreading and reduces ineffective strokes during powder return. The device includes a dual-sided powder supply box mounted above the build platform instead of below it. This allows spreading powder in both directions during build and return movements. The upper powder supply also reduces ineffective strokes compared to bottom-mounted powder boxes. The upper powder box has a tank, cover, and seals to prevent powder leakage.

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Powder supply device for accurate layer-by-layer feeding of gradient material powder in laser powder bed fusion (PBF) 3D printing. The device allows 3D printing of parts with varying compositions by supplying customized amounts of different powders in each layer. It uses a screw feeder, micro powder replenisher, and weighing system. The screw feeder supplies bulk powder, the replenisher adds small amounts, and the weighing system accurately dispenses predetermined amounts. This enables precise powder feeding for graded materials.

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A powder feeding device for laser cladding additive manufacturing that allows simultaneous deposition of multiple dissimilar powders in different areas during a single pass. The device has adjustable side-mounted powder tubes that can feed different powders synchronously to match the laser spot width. This enables partitioned broadband powder feeding for high-efficiency 3D printing of dissimilar materials under the same spot. The device adapts the powder feeding width to the spot size and optimally aligns the powder convergence area for metallurgical bonding. This allows broadband adjustable multi-tube synchronous powder feeding to improve cladding efficiency and quality compared to traditional narrow-band feeding.

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Laser cladding powder feeding system for additive manufacturing that enables real-time delivery and adjustment of multiple powder feed rates for laser cladding. It uses a static powder mixing unit to receive and mix the powders from separate supply units before dividing and feeding them to the nozzle. This simplifies the device compared to online mixing and allows fine-grained powder control. The mixed powder is divided evenly at the powder dividing unit. The static mixing reduces equipment complexity and size versus online mixing, while still enabling real-time powder adjustment.

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Selective laser sintering printer capable of printing parts using multiple powder materials without mixing them. The printer has a frame, powder storage, powder supply, powder spreading, forming, laser scanning, and powder recovery modules. The powder supply and spreading modules allow separate powder materials to be handled and spread without mixing. The forming module adjusts the mold cavity size as the part is printed. The recovery module returns excess powder between materials to prevent mixing.

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Selective laser sintering (SLS) 3D printing device with upper and lower powder supply and powder recycling to improve material utilization and enable mixed powder printing. The device has separate upper and lower powder supply boxes with different powders. The lower supply box has a lift mechanism to raise and lower the powder level. The upper supply box is connected to the powder spreading system. Powder recovered from the lower supply box goes to the left recycling box, while powder from the upper supply goes to the right recycling box. This allows mixing and recycling of powders during printing. The preheating chamber, laser, and powder spreading system are arranged above the build platform.

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Upper powder supply device for selective laser sintering printers that provides uniform and quantitative powder drop to improve quality and efficiency while reducing waste. The device has a silo, level gauge, observation window, discharge plate, motor, nut, limit switch, and stirrer. The silo narrows to a powder port. The discharge plate has a motor, limit switch, and optical axis seat. The plate moves along the axis to push powder. The stirrer inside the silo prevents agglomeration. The device allows monitoring powder levels and prevents low powder conditions.

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Powder filling and spreading system for large-scale additive manufacturing using laser melting that enables continuous powder replenishment during printing without pausing. The system has a main powder supply cylinder and an auxiliary powder supply cylinder connected to a powder replenishing cylinder. A powder restricting device prevents powder from falling in the build chamber. The main cylinder feeds powder to the spreader, and when low, the auxiliary cylinder takes over. A powder recovery system collects excess powder. This allows automatic powder replenishment when needed, preventing pauses for manual powder refills.

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An additive manufacturing method that uses impulses to settle and fluidize powder in a build chamber to improve part consistency and efficiency. The method involves delivering impulses to the build chamber to settle fresh and loose powder, then selectively jetting the binder onto the settled powder. This allows for the consistent part formation and gross depowdering.

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A relay powder feeding system for large-scale 3D printing that allows efficient powder transfer to the printing area as the build platform moves. The system uses a flexible telescoping hose to connect the powder hopper to the printing area. Motion compensation devices like guide sleeves prevent the hose from bending during reciprocating motion. This prevents powder shunting and ensures stable powder delivery for wide-width printing. A powder quantity monitoring system ensures optimal powder levels.

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Powder replenishment and spreading system for large-size laser selective melting equipment that enables continuous powder feeding and uniform spreading during additive manufacturing of large parts. The system has a primary powder supply cylinder and a secondary auxiliary cylinder that can assist in powder feeding when the main cylinder runs out. A powder restriction device in the build chamber prevents excess powder from falling. The build chamber has a moving substrate for layer-by-layer powder spreading. A control method coordinates the powder cylinders, spreading, and recovery systems to replenish powder without stopping printing.

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Powder preparation system for selective laser sintering 3D printers that improves the accuracy of mixing different powders for better print quality. The system has separate tanks for collected spilled powder, remaining powder, and new powder. Weighing modules in each tank measure the amounts. A conveyor transports powder between tanks. A control mechanism stops the conveyor at the correct weight for each powder. A stirrer mixes the powders. This allows precise mixing ratios compared to manual sorting and mixing.

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Method for feeding and spreading powder in laser sintering 3D printing to improve powder efficiency and reduce waste. It uses a quantitative powder feeding system with a bottom measuring cup to accurately dispense the exact amount of powder needed for each layer. This avoids overfeeding and prevents powder waste. The powder spreading device has a compacting motion to pack the powder and remove excess. A scraper removes powder from the build platform between layers. This reduces ineffective strokes and improves spreading efficiency. The powder falling piston has adjustable stroke to match layer thickness. The powder spreading distance is set based on part spacing. The system has aligned bottom measuring cup and scraper for consistent feeding.

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Orderly arrangement device and system for dissimilar powders in 3D printing to enable gradient material formation. The arrangement involves using a separate powder cylinder for each material, spreading one powder onto the build platform, and moving an adsorption device with micropores between the cylinders to pick up the second powder. This allows precise arrangement of dissimilar powders in a controlled pattern before sintering.

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A powder feeding system for laser melting machines that improves powder utilization and reduces waste compared to conventional powder feeders. The system has a powder bin above the build platform with three parallel pipes extending down. The pipes connect to a feeding cylinder and form a lattice structure. During feeding, multiple powder piles are formed on the platform. The build scraper removes excess powder from the top layer. This allows controlled spreading without excess powder entering the recycling cylinders. The lattice configuration ensures full coverage of the build area and eliminates powder loss.

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