3D Printing Layer Defect Correction via Selective Material Removal
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Solution Overview
Problem
Current 3D printing technologies face significant productivity and quality issues due to the need to discard entire objects when defects occur, leading to high costs and environmental impact, as well as time-consuming correction processes that can compromise the quality of the final product.
Innovation Solution
A device and method that utilize a monitoring and evaluation system to detect defects in 3D printed layers, allowing for targeted material removal of defective layers without interrupting the printing process, using a material removal device to correct errors by removing complete layers rather than partial ones, and a leveling device to prevent excess material issues, thus maintaining printing speed and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the entire object is discarded when a defect occurs during printing, then the quality of the final product is maintained, but the productivity and material efficiency deteriorate significantly
Solution Approach 1:
The patent divides the object into discrete layers and implements independent quality control for each layer. When a defect is detected in a specific layer, only that layer is removed rather than discarding the entire object. This segmentation allows selective correction of defective portions while preserving the rest of the object, thereby maintaining productivity and reducing material waste.
Solution Approach 2:
The patent extracts and removes only the defective layer from the multi-layer object using a material removal device. This selective extraction eliminates the need to discard the entire object when a defect occurs in a single layer, thus maintaining both high product quality and production efficiency.
2Manufacturing precision
If correction processes are implemented for each defect type, then the manufacturing precision is improved, but the complexity of the device and time consumption increase
Solution Approach 1:
The patent employs a universal material removal device that can handle all types of defects (insufficient material, excess material, geometric deviations) through a single standardized process. This multi-functional approach eliminates the need for multiple specialized correction devices and complex decision-making algorithms, simplifying the system while maintaining correction effectiveness.
Solution Approach 2:
The patent changes the approach from defect-type-specific corrections to a uniform parameter-based correction: removing complete layers from the defective layer upward. This parameter change simplifies the correction process by eliminating the need to identify and differentiate between various defect types, reducing device complexity and processing time.
3Manufacturing precision
If complete layers are removed instead of partial layers, then the manufacturing precision is maintained, but the amount of material removed increases
Solution Approach 1:
The patent applies a leveling device before the material removal device to create a uniform surface. This preliminary action ensures that when complete layers are removed, the maximum amount of material is eliminated while maintaining geometric precision. The leveling process optimizes the starting condition for layer removal, reducing unnecessary material waste.
4Manufacturing precision
If the printing process is interrupted for defect correction, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The patent implements continuous monitoring during the printing process using a monitoring device that detects defects in real-time. The system maintains continuous useful action by immediately removing defective layers upon detection without halting the overall printing process, thereby preserving productivity while ensuring manufacturing precision through continuous quality control.
Data Source
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AI summary
The invention relates to an apparatus (100) and a method for manufacturing a three-dimensional moulded article (200) by means of material application in layers Sn (n=1 to N), said apparatus comprising at least one material delivery device (300), a drive device (410), a printing substrate (400), a control device (500) having a data memory (510), and a material removal device (700). According to the invention, a monitoring device (600) is provided so that defects in a layer Sn, which may also occur later, i.e. after completion of said layer Sn, are also detected and eliminated. Furthermore, a downstream evaluation device (610) detects a layer Sx in which the at least one defect was detected. Subsequently, a default signal is generated and forwarded to the control device (500). The material removal device (700) completely removes the material of a partial region (T) of the moulded article (200) starting from the most recently printed layer SN up to the first of the defective layers Sx. The building up of the three-dimensional moulded object (200) starts again on layer Sx-1.