3D Printer Layer Dispensing Mechanism for Debris-Controlled Deposition
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Solution Overview
Problem
3D printing processes face issues with material debris accumulation on components, leading to functional disruptions and uneven layer deposition due to material adherence and obstruction, which affect the integrity and planarity of the printed object.
Innovation Solution
Implementing a layer dispensing mechanism protected by a labyrinth-type railing and a carriage with wheels or flexible couplers to maintain the path, coupled with an ancillary chamber for debris recycling and active/passive cleaning mechanisms to manage material and debris accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the layer dispensing mechanism operates in the processing chamber during 3D printing, then the material can be deposited onto the material bed, but debris accumulates on the mechanism and components, causing functional disruptions and altering component functions
Solution Approach 1:
The system is divided into separate functional zones: the processing chamber for material deposition and the ancillary chamber for housing the layer dispensing mechanism. The mechanism translates between these chambers, allowing material deposition while protecting the mechanism from debris accumulation in the high-energy processing zone.
Solution Approach 2:
The ancillary chamber serves as an intermediary space that houses the layer dispensing mechanism when not in use. This intermediate location protects the mechanism from direct exposure to debris-generating processes while still allowing it to perform its deposition function when needed.
2Ease of operation
If the layer dispensing mechanism translates through an opening in the partition, then the mechanism can access the material bed for deposition, but pre-transformed material may leak through the opening when the mechanism is retracted
Solution Approach 1:
The layer dispensing mechanism is extracted from the processing chamber and housed in the ancillary chamber when not actively depositing material. This separation eliminates the opening through the partition, thereby preventing material leakage while maintaining accessibility when needed.
Solution Approach 2:
The closure member proactively seals the opening in the partition before the layer dispensing mechanism is fully retracted into the ancillary chamber. This preliminary sealing action prevents pre-transformed material from leaking through the opening during the retraction process.
3Productivity
If the pre-transformed material is dispensed continuously, then the layer deposition process can proceed without interruption, but the material may clump up or adhere to surfaces, causing discontinuous flow
Solution Approach 1:
The layer dispensing mechanism incorporates vibration or oscillation to prevent pre-transformed material from clumping or adhering to surfaces during dispensing. This mechanical vibration maintains material flow uniformity and ensures continuous, uninterrupted deposition.
Solution Approach 2:
The system modifies physical parameters such as temperature, humidity, or surface properties of the dispensing mechanism to reduce material adhesion. These parameter changes maintain material flow stability while enabling continuous deposition.
4Loss of substance
If the closure member seals the opening to prevent material leakage, then material loss is reduced, but the layer dispensing mechanism cannot translate through the opening for deposition
Solution Approach 1:
The closure member is designed to be dynamic rather than fixed, allowing it to open when the layer dispensing mechanism needs to translate through the opening for deposition and close when the mechanism is retracted to prevent material leakage. This dynamic behavior resolves the contradiction between sealing and accessibility.
Data Source
AI summary
The present disclosure provides three-dimensional (3D) printing systems, apparatuses, methods and non-transitory computer readable media for the production of at least one requested 3D object. The 3D printer described herein facilitates operation of a layer dispensing mechanism with high precision albeit operating in an enclosure contaminated by debris, e.g., during the 3D printing. The debris may be a byproduct of the 3D printing.