3D Print Head Local Z Positioning for Varied Toolpaths
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Solution Overview
Problem
Existing extrusion-based 3D printers are limited by print head movement in only two directions, which restricts toolpaths and joint types, and changing print heads in a heated chamber introduces thermal control challenges and prolongs the build process.
Innovation Solution
A 3D printer with a local Z positioner and x-y gantry system allows print heads to move in three dimensions, including a separate tool chamber and calibration chamber, enabling high-speed, accurate positioning and exchange of print heads without disrupting thermal control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If print head movement is limited to two directions in a heated chamber, then thermal control is maintained, but toolpath variety and joint types are restricted
Solution Approach 1:
The positioning system is segmented into two independent subsystems: an x-y gantry for horizontal movement and a local Z positioner for vertical movement. This segmentation allows each subsystem to be optimized independently, enabling complex 3D toolpaths without requiring a completely complex repositioning mechanism.
Solution Approach 2:
The system transitions from 2D planar movement to 3D spatial movement by adding the local Z positioner that moves the print head vertically within the heated chamber. This dimensional addition enables varied toolpaths and joint types while maintaining thermal control.
2Reliability
If print head changing is performed in a heated chamber, then thermal control is maintained, but process time increases
Solution Approach 1:
The system prepares the alternative print head in advance by positioning it in the overhead tool holder before it is needed. When a print head change is required, the local Z positioner quickly retrieves the pre-positioned alternative head, eliminating the need for time-consuming chamber openings and external tool handling.
Solution Approach 2:
An overhead tool holder acts as an intermediary storage mechanism within the heated chamber. This intermediary structure allows multiple print heads to be kept ready at controlled temperatures, enabling rapid switching without disrupting the thermal environment or requiring external intervention.
3Reliability
If print head changing is performed in a heated chamber, then thermal control is maintained, but build process duration increases
Solution Approach 1:
The local Z positioner enables continuous printing operations by allowing rapid print head changes without interrupting the build process. The system maintains continuous material deposition by quickly swapping heads during layer transitions, eliminating idle time and maintaining productivity.
4Productivity
If high-speed positioning is implemented, then productivity increases, but positioning fidelity may be compromised
Solution Approach 1:
The local Z positioner incorporates feedback mechanisms that continuously monitor and adjust the print head position during high-speed movement. This feedback control ensures that positioning fidelity is maintained even at high speeds, allowing the system to achieve both productivity and precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-speed, accurate printing with varied toolpaths and seamless head changes, reducing thermal interference and process time, and maintaining print head fidelity during multi-material use.
Implementation Method 1
The local Z positioner includes a linear motor which moves the print head in the z-direction
Implementation Method 2
a primary z axis positioner which moves a build platen in a z-direction
Implementation Method 3
An x-y gantry positions the carriage in plane above and substantially parallel to an x-y build plane using an x linear motor and a y linear motor
Data Source
AI summary
A 3D printer includes a gantry configured to move in a plane substantially parallel to a x-y build plane and a print head configured to extrude molten material to print a 3D part in a layer-by-layer process. The 3D printer includes a platen configured to support the part being printed in the layer by layer process and positionable with a primary Z positioner along a z-axis substantially normal to the x-y build plane. The 3D printer includes a local Z positioner moved by the gantry, the local Z positioner comprising a linear motor configured to move the print head in the z-direction and having an operable range of motion extending from a nominal build position at which a nozzle of the print head is positioned in the x-y build plane to a raised position above the x-y build plane.