Automated 3D Printed Object Cleaning With Adaptive End Detection
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in efficiently and effectively removing caked, unfused build material from 3D printed objects, which can lead to reduced geometric accuracy, aesthetics, and functionality, and poses health risks to manual operators.
Innovation Solution
A robotic and automated system that extracts cleaning instructions associated with a 3D printed object, using a reader to identify grasping locations and decaking/cleaning operations, and a controller to instruct cleaning devices based on these instructions, ensuring precise and customized cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cleaning methods are used to remove caked build material, then operators can directly handle the cleaning process, but health risks increase and cleaning efficiency decreases
Solution Approach 1:
The patent replaces manual mechanical cleaning operations with an automated robotic system that uses controlled mechanical forces (brushes, air blasts, media blasts) to remove caked material. This substitution eliminates direct human exposure to harmful particles and chemicals while maintaining effective cleaning capability through programmated sequences of cleaning actions.
Solution Approach 2:
The cleaning system is designed to autonomously perform cleaning operations without human intervention. The robotic manipulator automatically positions cleaning tools, applies appropriate cleaning forces, and removes caked material based on pre-programmed instructions, making the system self-sufficient in performing the cleaning function that previously required human operators.
2Device complexity
If generic cleaning operations are used, then the cleaning process is simple, but geometric accuracy and surface quality of printed objects deteriorate
Solution Approach 1:
The patent applies different cleaning methods and forces to different regions of the printed object based on local requirements. The system identifies specific areas with caked material and applies appropriate cleaning intensities (gentle brushing for delicate areas, stronger media blasts for robust areas) to remove material without damaging geometric features or surface quality in each local region.
Solution Approach 2:
The cleaning system dynamically adjusts its operations based on real-time feedback and pre-programmed sequences. The robotic manipulator can modify cleaning forces, tool positions, and operation durations during the cleaning process to adapt to varying material accumulation patterns while preserving geometric accuracy through controlled, variable-intensity cleaning actions.
3Productivity
If automated cleaning systems are implemented, then safety and efficiency increase, but system complexity increases
Solution Approach 1:
The robotic cleaning system is designed with multi-functionality to handle various cleaning tasks using a single integrated platform. The system can perform multiple cleaning operations (brushing, air blasting, media blasting) with different tools and parameters, eliminating the need for multiple separate cleaning devices and reducing overall system complexity while maintaining high productivity.
Solution Approach 2:
The cleaning system incorporates feedback mechanisms that monitor cleaning progress and object characteristics in real-time. This feedback enables the system to automatically adjust cleaning parameters and operations, reducing the need for complex manual programming and control while improving cleaning efficiency through adaptive, intelligent operation based on actual conditions.
4Manufacturing precision
If intensive cleaning operations are applied to remove all caked material, then surface cleanliness improves, but risk of damaging the printed object increases
Solution Approach 1:
The system applies cleaning forces locally and selectively only to areas where caked material is present, rather than uniformly intensively cleaning the entire object. This localized approach removes surface contaminants to achieve high surface quality while concentrating cleaning energy only where needed, thereby preserving the structural integrity of the printed object in non-contaminated areas.
Solution Approach 2:
The cleaning system applies cleaning forces that are sufficient to remove caked material but controlled to avoid excessive action that could damage the object. By using partial action (cleaning only contaminated areas) and controlling the intensity within optimal ranges, the system achieves adequate surface cleanliness without over-cleaning that could compromise object strength or geometric features.
Data Source
AI summary
In one example in accordance with the present disclosure, a system is described. The system includes a reader to extract cleaning instructions associated with a three-dimensional (3D) printed object. The cleaning instructions include a termination condition to indicate when object cleaning is complete. The system also includes a controller to instruct at least one cleaning device to clean the 3D printed object based on the cleaning instructions. A measurement system of the system determines when the termination condition is met.