3D Printer Layer Height Adjustment for Wear Compensation

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Solution Overview

Problem

Existing three-dimensional structure manufacturing apparatuses face challenges in achieving high dimensional accuracy due to layer formation unit abrasion, leading to uneven powder layer thickness and reduced precision in forming complex structures.

Innovation Solution

A three-dimensional structure manufacturing apparatus that adjusts the distance between the formation unit and the layer formation unit based on the number of layers formed and the amount of abrasion, using a squeegee or roller as the layer formation unit, and incorporates a control unit to stop layer formation and adjust the position for uniform thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the layer formation unit is used repeatedly to form powder layers, then the productivity of three-dimensional object formation is improved, but the layer formation unit is abraded leading to uneven layer thickness and reduced manufacturing precision

Engineering Contradiction:

Improveformation speed of three-dimensional objectVSAvoiddimensional accuracy of three-dimensional structure

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention makes the distance between the layer formation unit and formation unit dynamically adjustable based on the number of layers formed. The control unit automatically adjusts this distance to compensate for abrasion of the layer formation unit, maintaining uniform layer thickness throughout the formation process. This dynamic adjustment resolves the contradiction by allowing repeated layer formation while preserving dimensional accuracy.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention implements a feedback mechanism where the control unit monitors the number of times layers have been formed and uses this information to automatically adjust the distance between the layer formation unit and formation unit. This feedback loop compensates for wear accumulation, enabling continuous operation without sacrificing precision. The system learns from usage patterns and self-corrects to maintain manufacturing precision.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If the layer formation unit operates continuously without adjustment, then the ease of operation is improved, but unevenness in powder layer thickness is generated reducing manufacturing precision

Engineering Contradiction:

Improveease of layer formation operationVSAvoiduniformity of powder layer thickness

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The invention enables the system to self-adjust and self-correct without manual intervention. The control unit automatically monitors layer formation count and adjusts the distance between components to compensate for wear. This self-service mechanism maintains manufacturing precision while keeping the operation simple and automated, resolving the contradiction between ease of operation and precision.

Inventive Principle:

Principle #25Self-service

3Device complexity

If the distance between formation unit and layer formation unit is fixed, then the device complexity is reduced, but manufacturing precision deteriorates due to layer formation unit abrasion

Engineering Contradiction:

Improvesimplicity of apparatus structureVSAvoiddimensional accuracy of formed structure

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The invention introduces a dynamic adjustment mechanism that automatically modifies the distance between components based on operational parameters. This dynamic element, controlled by the control unit monitoring layer formation count, adds minimal complexity while dramatically improving manufacturing precision by compensating for wear throughout the formation process.

Inventive Principle:

Principle #15Dynamics

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

This approach enables the production of three-dimensional structures with enhanced dimensional accuracy and uniform layer thickness, improving the precision and quality of complex structures by preventing unevenness caused by abrasion.

Implementation Method 1

a layer formation unit which forms the layers configured with the three-dimensional formation compositions on the formation unit... a distance between the formation unit and the layer formation unit is adjusted according to the number of times a layer is formed

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS10493655B2Three-dimensional structure manufacturing apparatus, manufacturing method of three-dimensional structure, and three-dimensional structure

Publication Date: 2019.12.03 SEIKO EPSON CORP

AI summary

Provided is a three-dimensional structure manufacturing apparatus which manufactures a three-dimensional structure by repeatedly forming layers by using three-dimensional formation compositions containing three-dimensional formation powders, the apparatus including: a formation unit in which the three-dimensional structure is formed; and a layer formation unit which forms the layers configured with the three-dimensional formation compositions on the formation unit, in which a distance between the formation unit and the layer formation unit is adjusted according to the number of times the layer is formed.