3D Printing Upstroke Force Control for Collision Prevention
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Solution Overview
Problem
Existing additive manufacturing techniques, particularly bottom-up stereolithography, lack efficient methods for industrial use, require manual tuning of velocity and acceleration, and are prone to damage from foreign objects and overloading, especially when producing objects with unvented cavities or flexible materials.
Innovation Solution
An apparatus and method using force sensors and controllers to regulate the speed and acceleration of the upstroke in additive manufacturing, incorporating collision detection with multiple force sensors to prevent damage and automate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tuning of velocity and acceleration is used in additive manufacturing, then the process can be controlled, but the ease of operation deteriorates and time is lost
Solution Approach 1:
The patent implements force feedback control where force sensors continuously monitor the force applied during the upstroke, and the controller automatically adjusts velocity and acceleration based on the sensed force to maintain it near a target value. This eliminates manual tuning while preserving process control through automated closed-loop control.
2Productivity
If high speed and acceleration are used in additive manufacturing, then productivity is improved, but the risk of damage from foreign objects and overloading increases
Solution Approach 1:
The patent employs force monitoring and feedback control that detects abnormal forces indicating foreign objects or overloading conditions before they cause damage. The system automatically reduces speed and acceleration when force thresholds are exceeded, providing protective action in advance to prevent mechanical component damage while maintaining high productivity during normal operation.
3Ease of operation
If force feedback control is implemented, then ease of operation is improved and manual tuning is eliminated, but device complexity increases
Solution Approach 1:
The patent replaces complex manual mechanical tuning mechanisms with an automated electronic control system that uses force sensors and feedback algorithms. This substitution eliminates the need for operator intervention and manual adjustments, improving ease of operation despite the added electronic control complexity.
4Reliability
If force sensors and feedback control are added, then reliability is improved by preventing damage, but device complexity increases
Solution Approach 1:
The patent implements force feedback control where force sensors continuously monitor the force applied during the upstroke, and the controller automatically adjusts velocity and acceleration based on the sensed force to maintain it near a target value. This eliminates manual tuning while preserving process control through automated closed-loop control.
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
Reduces the need for manual tuning, minimizes damage to mechanical components, and effectively detects and prevents collisions with foreign objects, enabling the production of high-quality three-dimensional objects with complex geometries.
Implementation Method 1
a light source configured to irradiate the build region through the window to form a solid polymer from the polymerizable liquid
Data Source
AI summary
A method of forming a three-dimensional object includes: (a) providing an apparatus (b) vertically reciprocating a carrier with respect to a build surface in an upstroke and a downstroke to form a build region between a growing object and the build surface, and to fill the build region with the polymerizable liquid, while also: (i) sensing force exerted between the carrier and the build surface through the growing object and the polymerizable liquid during the upstroke; and (ii) modifying the speed and/or acceleration of the upstroke in response to the sensed force so that the sensed force approaches a predetermined target force; then (c) irradiating the build region with light to form a new portion of the object from the polymerizable liquid on the growing object; and then (d) repeating steps (b) through (c) to form additional portions on the growing object until the three-dimensional object is formed.