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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A process to make polyolefin powders for 3D printing that have a small size, narrow size distribution, spherical shape, high density, and good flowability. The process starts with the aqueous dispersion of polyolefin particles containing a high-melting ethylene-based polymer, a polyolefin wax, and an acrylic dispersant. The dispersion is diluted, the solid particles collected, washed to remove excess dispersant, and dried to form the powder.

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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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Apparatus and method for preconditioning powder before calendering in 3D printing. The powder is dispensed on a substrate, and then a conditioning agent is applied to increase powder cohesiveness before compacting. This ensures uniform compaction and prevents powder from sticking and splitting during calendering. The conditioning agent can be steam to avoid damage.

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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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