Abstract
The most successful additive manufacturing (AM) technologies are based on thelayer-by-layer depositionof a flowable powder. Although considered as the third industrial revolution, one factor still limiting these processes to become completely autonomous is the often necessary build-up of support structures. Besides the prevention of lateral shifts of the part during the deposition of layers, the support assures quality and stability to the built process. The loose powder itself surrounding the built object, or so-called powder-bed, does not provide this sustenance in most existent technology available. Here we present a simple but effective and economical method for stabilizing the powder-bed, preventing distortions in the geometry with no need for support structures. This effect, achieved by applying an air flow through the powder-bed, is enabling an entirely autonomous generation of parts and is a major contribution to all powder-based additive manufacturing technologies. Moreover, it makes powder-based AM independent of gravitational forces, which will facilitate crafting items in space from a variety of powdery materials.
Highlights
Additive manufacturing (AM) describes a class of technologies in which a 3D object is directly generated from a virtual model by adding material in a layer-by-layer approach defined by ASTM F2792-12a (Standard Terminology for Additive Manufacturing Technologies) as the “process of joining materials to make objects from 3D model data, usually layer upon layer, opposed to subtractive manufacturing methodologies, such as traditional machining” [1]
In order to apply an air flow through the powder-bed in a 3D printing process, a commercial 3D printer has been modified according to the proprietary setup in Figure 2: the bottom side of the building platform is connected to a vacuum pump applying vacuum to one side of the powder-bed, resulting in a pressure gradient which creates an air flow through the powder
The application of an air flow through the powder has been demonstrated as an effective method for stabilizing the powder-bed during the layer-by-layer deposition
Summary
Additive manufacturing (AM) describes a class of technologies in which a 3D object is directly generated from a virtual model by adding material in a layer-by-layer approach defined by ASTM F2792-12a (Standard Terminology for Additive Manufacturing Technologies) as the “process of joining materials to make objects from 3D model data, usually layer upon layer, opposed to subtractive manufacturing methodologies, such as traditional machining” [1]. While the need for flexibility in design had first priority at that time, nowadays the physical and functional properties of the generated parts are a major concern, for example, in emerging fields as tissue engineering [4], complex functional, and lightweight structures [5]. In this context even applications in space are currently being tested, where the diversity of tools and spare parts directly relates to the mass to be carried into space [6]. Additive manufacturing is a step further in the direction towards an autonomous manufacture, as the geometry of a part to be built does not imply a certain machine setup
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