3D Printer Skew Calibration Without External Reference Objects
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Solution Overview
Problem
Existing 3D printing systems face inaccuracies due to skew in movement components and deviations from precise alignment, and are challenged by thermal expansion and moisture absorption, which affect dimensional accuracy without the use of an independent reference object.
Innovation Solution
An apparatus and method that utilizes a 3D printer with integrated sensors and controllers to print features in specific directions, measure positional data after rotation, and determine skew without an independent reference object, while also compensating for thermal expansion and moisture absorption by adjusting print parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an independent reference object is used for skew calibration, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system uses the 3D printer itself to print calibration features on the build plate, eliminating the need for external reference objects. The printer's own movement components and build plate serve as the calibration reference, allowing the system to self-calibrate without additional equipment.
Solution Approach 2:
The build plate serves multiple functions: it is both the printing surface for manufacturing parts and the reference frame for skew calibration. The calibration features are printed directly on the build plate, allowing the same component to serve dual purposes in manufacturing and calibration.
2Measurement precision
If an independent reference object is used for skew calibration, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
Instead of using expensive, precision-machined reference objects, the system prints calibration features directly on the build plate using standard 3D printing materials. These printed features are sufficient for calibration purposes and eliminate the need for costly external reference standards.
Solution Approach 2:
The system generates its own calibration references by printing features on the build plate, eliminating the need to purchase or maintain separate reference objects. This self-generated approach reduces external dependencies and costs.
3Manufacturing precision
If printer components are precisely aligned to eliminate skew, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system measures the actual positions of printed calibration features and uses this feedback to calculate skew angles. This measured skew information is then used to adjust movement commands, creating a closed-loop system that compensates for misalignment without requiring perfect mechanical alignment.
Solution Approach 2:
Instead of physically adjusting mechanical components to achieve perfect alignment, the system changes the software parameters (movement commands) to compensate for the fixed mechanical skew. This software-based parameter adjustment is simpler than mechanical realignment.
4Manufacturing precision
If compensation for thermal expansion and moisture absorption is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system pre-calculates compensation values for thermal expansion and moisture absorption based on material properties and environmental conditions. These compensation values are applied to the 3D production file before printing, allowing the system to proactively counteract expected dimensional changes rather than reacting to them after they occur.
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 accurate skew detection and correction, and compensates for thermal expansion and moisture absorption, enhancing the precision of 3D printed parts without the need for expensive reference objects.
Implementation Method 1
compensating for coefficient of thermal expansion
Implementation Method 2
compensating for coefficient of thermal expansion and moisture absorption
Data Source
AI summary
A 3D printing apparatus and method corrects for skew in the motion components of the apparatus without the use of an independent reference object. A calibration object having features therein or thereon is printed. A user rotates the calibration object by a certain angle after it is printed. The features in/on the calibration object are measured, and an amount of skew is determined based on the measurements. In addition, a 3D printing operation is compensated based on the effects of a coefficient of thermal expansion and/or moisture absorption on dimensional changes.