3D Printing Weight Feedback for In-Process Quality Calibration
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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, limiting their application in fields requiring hyper-accurate quality results.
Innovation Solution
A system and method for multidimensional printing that includes a multidimensional printer with a printing head, printing surface, axis system, and scale, where a control unit measures and compares the weight of the printed object with a reference weight to control the printing head's extrusion, ensuring the printed object meets desired quality standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If external sensors are used for calibration in conventional 3D printing, then calibration can be performed, but the cost increases and the process becomes more complex
Solution Approach 1:
The printing surface is equipped with an integrated scale that enables the printing system to perform self-calibration without requiring external sensors. The scale measures the actual position and dimensions of printed test patterns, allowing the system to automatically adjust and correct printing parameters, thereby achieving calibration while reducing device complexity and cost.
Solution Approach 2:
The printing surface serves multiple functions: it acts as both the substrate for printing and as a measurement platform through the integrated scale. This multi-functional design eliminates the need for separate external calibration devices, reducing system complexity while maintaining calibration accuracy.
2Manufacturing precision
If conventional calibration systems are used, then calibration can be performed at beginning or end, but accurate customization of printing parameters during the process cannot be achieved
Solution Approach 1:
The scale on the printing surface provides real-time feedback during the printing process by measuring the actual dimensions and position of printed test patterns. This feedback is used by the control system to dynamically adjust printing parameters mid-process, enabling accurate customization without requiring calibration only at the beginning or end, thus improving both precision and timing flexibility.
Solution Approach 2:
A test pattern is printed preliminarily on the printing surface before the actual printing process. This test pattern serves as a reference for calibration, allowing the system to pre-adjust printing parameters based on measured deviations, thereby ensuring accurate customization from the start of the actual printing process.
3Manufacturing precision
If multiple external sensors are used for calibration, then calibration coverage can be improved, but the overall cost of the printing process increases
Solution Approach 1:
The printing surface with integrated scale performs self-calibration functions, eliminating the need for multiple external sensors. This self-service approach maintains comprehensive calibration coverage while significantly reducing the quantity of calibration components required, thereby lowering the overall cost of the printing process.
4Productivity
If conventional printing processes are used without proper calibration, then productivity is high, but quality control fails and objects are rejected
Solution Approach 1:
The scale provides real-time feedback on printed object dimensions and position, enabling the control system to immediately detect and correct deviations from specifications. This feedback mechanism ensures quality control without significantly impacting productivity, as corrections are made automatically during or immediately after the printing process, preventing rejection and maintaining high production speed.
Solution Approach 2:
Calibration is performed preliminarily using a test pattern before actual production printing. This preliminary calibration ensures that the printing system is properly configured, thereby maintaining both high productivity and reliable quality control from the start of production, preventing rejections and ensuring consistent quality.
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
The system provides efficient quality analysis and calibration, reducing waste and costs by ensuring the printed object meets quality standards, making it suitable for applications requiring high accuracy, such as bioprinting and pharma printing.
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.