3D Printing Workflow That Decouples Voxel Deposition From Locking
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Solution Overview
Problem
Existing three-dimensional printing systems are limited by locking delays, particularly with materials like concrete, which can take hours or days to solidify, significantly slowing down the printing process and requiring manual intervention for complex structures.
Innovation Solution
The system separates the data transfer stage from the locking stage, allowing multiple objects to be printed independently, with the locking process occurring in parallel, using multi-dimensional printheads or fill materials to support the printed voxels until they solidify.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material locking time is reduced to increase printing speed, then productivity improves, but manufacturing precision deteriorates
Solution Approach 1:
The system divides the printing process into two independent stages: data transfer (printing) and locking. Multiple layers can be printed in sequence without waiting for each layer to lock, as the locking process occurs independently after printing. This segmentation allows printing speed to be decoupled from locking time, resolving the contradiction between productivity and precision.
Solution Approach 2:
The system performs preliminary support structure creation before printing subsequent layers. Fill material is deposited and support structures are formed in advance to hold unlocked material in place, enabling faster printing without compromising precision. The support structures are prepared beforehand to maintain layer integrity during the reduced locking intervals.
2Manufacturing precision
If locking time is extended to ensure layer stability, then manufacturing precision improves, but productivity deteriorates
Solution Approach 1:
The printing and locking operations are segmented into separate, concurrent processes. Printing continues at full speed depositing multiple layers while locking occurs independently in the background. This eliminates the sequential dependency where printing must wait for locking, thereby maintaining layer stability while maximizing printing throughput.
Solution Approach 2:
The system maintains continuous printing action without interruption for locking. Material is continuously deposited layer after layer while the locking process operates independently. This continuity of useful action ensures maximum productivity while the support structures maintain layer stability throughout the process.
3Manufacturing precision
If support structures are added to maintain layer integrity, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The printhead system is designed with multi-functionality, capable of both printing material and depositing fill material for support structures in a single integrated unit. This universal design provides the necessary layer support integrity while avoiding the complexity of separate support deposition systems, as one printhead performs multiple functions.
Solution Approach 2:
The system uses homogeneous material properties where fill material and printing material are deposited through the same printhead mechanism. This homogeneity in deposition method simplifies the device architecture while still providing the necessary support structures for layer integrity, avoiding the need for complex specialized support mechanisms.
Data Source
AI summary
This disclosure provides various systems and methods for three-dimensional printing in which data describing an object as a plurality of voxels is transferred as a print material to form the three-dimensional object independent of locking. That is, various systems and methods are provided herein in which the three-dimensional printing step is to transfer data representing various voxels into a corresponding physical object via a three-dimensional printer. The first step is repeated until all the voxels are printed without waiting for any of the voxels of print material to lock. Accordingly, the three-dimensional printer can be used to print at least one subsequent object while the first object finishes locking.