3D Printing Reorientation for Complex Geometries
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Solution Overview
Problem
Conventional 3D printing technologies face limitations in printing complex geometries due to the need for support material, which adds complexity and cost, as the print head is restricted by the substrate and often requires mechanical removal of support material after printing.
Innovation Solution
A method involving reorientation of printed parts on a substrate during the 3D printing process without additional support, using a robotic arm and computer-controlled spray head to apply print material from a spray head, allowing for targeted placement and bonding of discrete portions, potentially eliminating the need for support material by flipping and re-engaging parts with the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support material is used to hold printed material during 3D printing, then the stability and structural integrity of the printed item is improved, but the device complexity and post-processing requirements increase due to the need for mechanical removal of support material
Solution Approach 1:
The patent extracts and removes the substrate from the printing system entirely, allowing parts to be supported and reoriented during printing without requiring support material. This eliminates the complex post-processing step of removing support material while maintaining structural integrity through strategic reorientation of the part on the substrate during the printing process
Solution Approach 2:
The patent introduces dynamic reorientation of the part on the substrate during the printing process. By periodically changing the orientation of the part (e.g., flipping between horizontal and vertical positions), the system maintains optimal printing conditions and eliminates the need for support material, thereby reducing device complexity while preserving structural integrity
2Ease of operation
If the print head is restricted to applying material only to open portions of the item, then the ease of operation is improved, but the adaptability to print complex geometries deteriorates
Solution Approach 1:
The patent makes the part dynamic by periodically reorienting it on the substrate during printing. This allows the print head to maintain its simple operation of depositing material only on exposed surfaces, while the reorientation enables printing of complex geometries that would otherwise require support material or inaccessible positioning
Solution Approach 2:
The patent adds the dimension of time-varying orientation to the printing process. By flipping the part between different orientations (horizontal, vertical, inverted) during printing, the system expands the range of printable geometries without complicating the print head's fundamental operation
3Manufacturing precision
If support material is used to prevent deformation under gravity, then the manufacturing precision is improved, but the loss of substance increases due to printing and discarding support material
Solution Approach 1:
The patent removes support material from the system entirely by using substrate-based reorientation strategies. The part is flipped and repositioned on the substrate during printing to maintain manufacturing precision without requiring any support material, thereby eliminating the waste associated with printing and discarding support material
Solution Approach 2:
The part itself serves its own support function through strategic reorientation on the substrate. By periodically flipping the part to different orientations, the already-printed portions of the part provide structural support for subsequent printing operations, eliminating the need for separate support material and the associated waste
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 the creation of complex geometries with reduced or eliminated support material, simplifying the printing process and eliminating the need for post-print support removal, while enhancing bonding strength through surface preparation and material property optimization.
Implementation Method 1
the item is built up from print material cold sprayed from a spray head
Data Source
AI summary
A method of 3D printing an item, includes printing part of the item in three dimensions on a substrate, reorienting the part with respect to holding means that holds the part or substrate, and printing a further part of the item in three dimensions on the first mentioned part.