Optimized design and key performance factors of a gas circulation filtration system in a metal 3D printer

To further improve the quality of parts in metal 3D printers, it is necessary to optimize the structure and study the performance of their gas circulation filtration systems. First, we used the parametric modeling method to complete the formed cavity modeling. We then optimized the design of the air inlet structure of the formed cavity using the moldflow simulation method, and finally, we evaluated the optimized design results through assembly experiments and measurements of the molded parts’ components. The combination of parametric modeling and moldflow simulation methods produced a high modeling efficiency and had a good effect on the optimized design of the gas circulation filtration systems. After optimizing the design, the turbulence intensities and distribution areas of the formed cavities were reduced. During the 3D printing of the curved guide plate, the plane of the guide plate holder was inclined 55° relative to the machining datum plane, which improved the form quality. The 3D printed curved guide plate closely matched the inlet end of the printer’s air duct, and the upper guide plate was fixed at a suitable position using screws. The niobium contents of the parts formed by the guide plate in Design 2 were low, which lays a foundation for the 3D printing of high-performance metal parts.