3D Production Machine with Continuous Calibration and Self-Correction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current 3D production machines face inefficiencies when producing components with multiple materials, as they often require multiple machines and processes, leading to increased costs and time due to lack of continuous monitoring and corrective actions during production.

Innovation Solution

A 3D production system with multi-axis-rotation, continuous scanning, and the use of certified gauge blocks for accurate measurement and calibration, combined with both additive and subtractive action tools, enabling real-time monitoring and self-correction during the production process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple machines and processes are used to produce components with multiple materials, then material variety is improved, but production time and cost increase

Engineering Contradiction:

Improvematerial varietyVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent combines multiple material deposition capabilities into a single 3D production machine, integrating different material sources and deposition mechanisms to handle multiple materials (metals, ceramics, polymers) without requiring separate machines or processes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The machine is designed with universal functionality to deposit various material types through different mechanisms (droplet, fiber, powder) using a single integrated system, allowing one machine to perform multiple material processing functions that previously required separate specialized equipment

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If visual testing is done at the end of production, then measurement accuracy is improved, but material waste increases

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidmaterial waste

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The system implements continuous visual feedback during the production process using cameras and sensors to monitor deposition quality in real-time, enabling immediate detection of defects and adjustments before the entire part is completed, thus preventing material waste from producing defective parts

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary visual inspection and measurement during the production process rather than waiting until the end, allowing early detection of issues and corrective actions to be taken before completing the entire part, thereby preventing material waste

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If encoders on motors are used for feedback, then process simplicity is improved, but measurement accuracy deteriorates

Engineering Contradiction:

Improveprocess simplicityVSAvoidmeasurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical encoder-based feedback systems with optical vision systems and sensors that directly measure the physical geometry and position of deposited materials, substituting indirect mechanical measurement with direct optical measurement for higher accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If continuous monitoring and self-correction are implemented, then productivity is improved, but device complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system incorporates self-correction capabilities where the automated vision system detects defects and the control system automatically adjusts deposition parameters or triggers corrective actions without human intervention, enabling the system to monitor and correct itself continuously during production

Inventive Principle:

Principle #25Self-service

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

This system allows for continuous, efficient production of complex parts with mixed materials by continuously monitoring and correcting errors in real-time, reducing material waste and time-to-production.

Implementation Method 1

makes novel use of a certified gauge block for accurate measurement and calibration support

Methodology Applied

Scientific EffectPhysical comparison measurement:

Implementation Method 2

combination both additive (deposition) and subtractive (ablation) action tools

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Implementation Method 3

combination both additive (deposition) and subtractive (ablation) action tools

Methodology Applied

Scientific EffectAblation: Ablation

Data Source

PatentUS20240310816A13D Production Machine with Continuous Process, Calibration and Self-Corrrection

Publication Date: 2024.09.19 GRAYSTON RYLAN HARRY

AI summary

The invention herein disclosed is 3D production system combining both additive and subtractive action tools, continuous processing, continuous calibration monitoring and adjustment, a certified gauge block, and identification of opportunities to alter process flow and shorten time while self-correcting.