Powder bed fusion is a variant of the additive manufacturing process, in which a component is fabricated using a powder layer which is spread over a build platform using a roller or a doctor blade. The layer is scanned with a heat source (commonly LASER) to fuse the particles together and create a layer. Spreading a uniform and smooth layer with high repeatability is the key factor in deciding the mechanical properties of the final product. In the current study, a novel gravity-based technique of producing the powder layer is proposed. To demonstrate the capability of the system a miniaturized model is simulated on Altair EDEM® software. The system consists of a hopper at some height from the substrate. When subjected to vibration, the hopper delivers powder through the opening beneath it. This hopper is then given a motion in a desired direction to produce a powder layer over the substrate. Three different types of hoppers are tested which vary in terms of openings present. The first hopper consists of a narrow slot, while the second hopper consists of multiple rectangular slots and the last one consists of multiple openings of circular shapes. A mass sensor is placed on the bed to check the uniformity in all the three cases. Mass flow analysis of the bed reveals that a more uniform powder layer is forming with the second hopper.

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Preparation of a Powder Layer Using the Gravity-Based Non-contact Type Powder-Spreading System

  • Aakash Tyagi,
  • Manas Das,
  • Sajan Kapil

摘要

Powder bed fusion is a variant of the additive manufacturing process, in which a component is fabricated using a powder layer which is spread over a build platform using a roller or a doctor blade. The layer is scanned with a heat source (commonly LASER) to fuse the particles together and create a layer. Spreading a uniform and smooth layer with high repeatability is the key factor in deciding the mechanical properties of the final product. In the current study, a novel gravity-based technique of producing the powder layer is proposed. To demonstrate the capability of the system a miniaturized model is simulated on Altair EDEM® software. The system consists of a hopper at some height from the substrate. When subjected to vibration, the hopper delivers powder through the opening beneath it. This hopper is then given a motion in a desired direction to produce a powder layer over the substrate. Three different types of hoppers are tested which vary in terms of openings present. The first hopper consists of a narrow slot, while the second hopper consists of multiple rectangular slots and the last one consists of multiple openings of circular shapes. A mass sensor is placed on the bed to check the uniformity in all the three cases. Mass flow analysis of the bed reveals that a more uniform powder layer is forming with the second hopper.