3D Printer Weight Feedback for Real-Time Print Quality Control
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Solution Overview
Problem
Conventional 3D printing processes lack effective calibration systems, leading to inaccurate customization of printing parameters and the production of undesired quality objects, which are often rejected, and are costly due to the use of external sensors for calibration.
Innovation Solution
A system and method for multidimensional printing that includes a multidimensional printer with a printing head, printing surface, axis system, and scale, controlled by a control unit to measure and compare the weight of the printed object with a reference weight, stopping extrusion when the desired quality is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are used for calibration, then calibration can be performed, but the cost increases and the process becomes more complex
Solution Approach 1:
The patent integrates the calibration function directly into the printing head by incorporating a scale within the printing surface assembly. This merging of the calibration device with the printing device eliminates the need for separate external sensors, thereby reducing system complexity while maintaining calibration capability. The scale is positioned to directly measure the weight of printed objects during the printing process,实现ing calibration without additional external components.
Solution Approach 2:
The printing head performs calibration measurements autonomously using the integrated scale during the normal printing process. The system self-calibrates by measuring the weight of printed objects and adjusting parameters accordingly, without requiring external calibration equipment or separate calibration procedures. This self-service approach simplifies the overall system while maintaining measurement precision.
2Measurement precision
If external sensors are used for calibration, then calibration can be performed, but the overall cost of the printing process increases
Solution Approach 1:
By combining the calibration function with the printing head through an integrated scale, the patent eliminates the need to purchase and install separate external sensor systems. This integration reduces the overall bill of materials and system cost while maintaining the necessary calibration accuracy for quality control.
Solution Approach 2:
The self-calibrating capability using the integrated scale eliminates the need for external calibration services, specialized calibration equipment, and additional manual calibration procedures. This reduces both capital expenditure and operational costs associated with calibration activities.
3Productivity
If calibration is performed only at the beginning or end of printing, then external devices can be used, but real-time quality control during printing is not achieved
Solution Approach 1:
The integrated scale enables continuous weight measurement of printed objects throughout the printing process. The control unit continuously monitors the weight and compares it with the target weight, allowing real-time adjustments to be made during printing. This continuous measurement and control ensures both high productivity and consistent manufacturing precision without interrupting the printing workflow.
Solution Approach 2:
The system implements a feedback loop where the scale continuously measures the weight of the printed object, the control unit compares the measured weight with the target weight, and adjusts the printing parameters in real-time based on the deviation. This closed-loop feedback control ensures real-time quality control while maintaining continuous production, resolving the contradiction between productivity and precision.
4Measurement precision
If multiple sensors are used for calibration, then comprehensive calibration can be achieved, but the number of components and system complexity increases
Solution Approach 1:
The patent consolidates multiple calibration functions into a single integrated scale within the printing head. This single device performs comprehensive weight measurement and calibration, replacing what would otherwise require multiple separate sensors and calibration devices. The integration maintains comprehensive calibration capability while significantly reducing the number of components.
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
Ensures the production of high-quality printed objects by real-time quality analysis, reducing waste and costs by integrating a scale within the printer, eliminating the need for external sensors and improving calibration efficiency.
Implementation Method 1
a scale, wherein the scale is arranged to measure weight applied on the printing surface
Data Source
AI summary
A system for performing quality analysis for multidimensional printing. The system includes a multidimensional printer, wherein the multidimensional printer comprises a printing head, a printing surface, an axis system and a scale, wherein the scale is arranged to measure weight applied on the printing surface; and a control unit operatively coupled to the multidimensional printer. The control unit is configured to control the printing head to extrude a printing material, to produce a printed object on the printing surface, obtain, from the scale, a weight of the printed object, and store the weight of the printed object in a memory associated with the control unit, compare the weight with a reference weight of the printed object, and control the printing head to stop extrusion of the printing material when the weight is equal to or exceeds the reference weight.