Partitioned 3D Printer Chambers for Tip Calibration and Thermal Isolation
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Solution Overview
Problem
Existing 3D printers lack the ability to efficiently manage multiple functionalities with a single print head, leading to inaccuracies and inefficiencies due to variations in print head positioning and thermal management.
Innovation Solution
A 3D printer with a gantry system that includes a plurality of partitioned chambers, a thermal barrier, and a local Z positioner, allowing for precise movement and calibration of print heads between chambers, ensuring consistent tip location and thermal isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single print head is used for multiple functionalities, then device complexity is reduced, but manufacturing precision deteriorates due to positioning variations
Solution Approach 1:
The build chamber is segmented into multiple partitioned chambers (first chamber, second chamber, third chamber) with different functionalities (printing chamber, calibration chamber, support chamber). The print head is sequentially moved between these segmented chambers to perform different operations, maintaining precision through dedicated chamber functions while using a single print head.
Solution Approach 2:
A thermal barrier is introduced as an intermediary element between the first chamber (printing chamber) and second chamber (calibration chamber) to isolate thermal environments. This thermal barrier maintains consistent tip location by preventing thermal interference between chambers while allowing the print head to move between them.
2Device complexity
If multiple functionalities are integrated in one chamber, then device complexity is reduced, but thermal management deteriorates due to thermal interference
Solution Approach 1:
The build chamber is divided into multiple partitioned chambers (first chamber for printing, second chamber for calibration, third chamber for support) to segregate different thermal environments. This segmentation prevents thermal interference between heating operations and calibration operations while maintaining manageable device complexity through organized spatial separation.
Solution Approach 2:
Thermal barriers are positioned between chambers as intermediary elements to block thermal interference. Specifically, a thermal barrier is placed between the first chamber (where heating occurs) and the second chamber (where calibration occurs), and another thermal barrier is positioned between the first chamber and third chamber, isolating thermal effects to their respective chambers.
3Productivity
If print head moves quickly between chambers, then productivity is improved, but manufacturing precision deteriorates due to positioning inaccuracies
Solution Approach 1:
A calibration chamber (second chamber) is provided where the print head can perform preliminary calibration of its tip location before entering the printing chamber. This preliminary action ensures accurate positioning for high-precision printing operations, enabling fast movement between chambers without sacrificing precision through pre-positioning in the dedicated calibration chamber.
Solution Approach 2:
Different chambers are designed with local quality characteristics optimized for their specific functions: the calibration chamber provides a controlled environment for precise tip location calibration, the printing chamber provides optimal conditions for high-precision printing, and the support chamber provides structural support. This local optimization allows fast movement between chambers while maintaining precision in each functional zone.
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 and efficient printing by maintaining consistent print head tip location, reducing thermal interference, and facilitating multi-functional operations, thereby enhancing the quality and precision of printed parts.
Implementation Method 1
a thermal barrier spanning the plurality of partitioned chambers and located above the upper edges of the plurality of partitioned chambers
Implementation Method 2
a gantry configured to move in a plane and in a direction substantially normal to the plane
Implementation Method 3
a local Z positioner configured to adjust a position of the print head in the direction substantially normal to the plane
Data Source
AI summary
A 3D printer includes a gantry configured to move in a plane and in a direction substantially normal to the plane and at least one print head carried by the gantry, the at least on print head comprising an extrusion nozzle at a bottom end. The 3D printer includes a plurality of partitioned chambers accessible by the at least one print head, each of the partitioned chambers having an upper edge defining an opening into each of the plurality of chambers, and a platen within a first chamber of the plurality of chambers, the platen configured to receive material from the print head to print the 3D part. The at least one print head is configured to be moved between each of the plurality of partitioned chambers by raising the print head in the direction substantially normal to the plane such that the extrusion nozzle is above the upper edge of the plurality of chambers, moving the print head in the plane from a first location above the first chamber of the plurality of partitioned chambers to a second location above a second chamber of the plurality of partitioned chambers and lowering the at least one print head into the second chamber.