3D Printer In-Process Sensor Verification of Print Parameters
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Solution Overview
Problem
Existing 3D printing technologies lack efficient in-process non-destructive testing methods to validate print parameters, leading to inefficiencies and inaccuracies in verifying the implementation of selected print/process parameters in the printed object.
Innovation Solution
An apparatus and method utilizing a sensor set integrated with a 3D printer to perform in-process testing, including sensors like laser scanners, cameras, and ultrasonic sensors to monitor and verify print parameters such as fiber placement, infill density, and external feature insertion during the printing operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If post-production analysis (destructive testing or X-ray examination) is applied to validate printing operations, then the ability to detect printing defects is improved, but the time required and material waste increase
Solution Approach 1:
The patent implements in-process testing during the printing operation itself, rather than waiting for post-production analysis. Sensors monitor printing parameters (temperature, extrusion rate, layer height) in real-time, allowing defects to be detected and addressed during printing, thereby reducing time and material waste associated with post-production testing
Solution Approach 2:
The system continuously monitors printing parameters through sensors and provides real-time feedback to the control system. This feedback loop enables dynamic adjustment of printing parameters and immediate detection of deviations from specified tolerances, eliminating the need for time-consuming post-production analysis
2Measurement precision
If post-production analysis is used to validate printing operations, then the ability to detect printing defects is improved, but material waste increases
Solution Approach 1:
By performing testing during the printing process rather than after production, the system can identify and correct defects before they result in wasted material. This preliminary detection and correction capability significantly reduces material waste compared to post-production analysis methods
3Reliability
If in-process non-destructive testing is implemented, then the need for destructive testing is reduced, but device complexity increases
Solution Approach 1:
The patent integrates multiple sensing functions into a unified in-process testing system that can monitor various printing parameters (temperature, extrusion rate, layer height, dimensional accuracy) using a single integrated sensor array and control system, thereby managing complexity while achieving comprehensive validation
Solution Approach 2:
The printing system performs self-validation through integrated sensors that monitor its own operation. The system tests itself during printing without requiring external destructive testing equipment, using embedded sensors to verify print parameters and detect defects in real-time
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 real-time validation of print parameters, reducing material waste and time by ensuring accurate and precise printing without destructive or costly post-print testing, thereby improving the fidelity and reliability of 3D printed objects.
Implementation Method 1
The sensor set 200 may include a laser scanner 15
Data Source
AI summary
A 3D printing apparatus and method confirms that one or more print parameters was satisfied in the printing of a 3D object. Sensor readings are obtained during the printing of the 3D object. Based on sensor data corresponding to the sensor readings, a confirmation is made as to whether the one or more print parameters was satisfied in the printing of the 3D object.