Additive Manufacturing System with Real-Time Data Cloud Comparison
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Solution Overview
Problem
Existing continuous fiber 3D printing systems face limitations in structure strength and operational efficiency, particularly in the fabrication of composite structures, as they do not effectively utilize continuous fiber reinforcement to enhance the structural integrity and accuracy of manufactured components.
Innovation Solution
An additive manufacturing system that includes a print head configured to discharge a continuous reinforcement material, with a support mechanism for moving the print head, a receiver to generate signals for shape, size, and location, and a processor to create a data cloud and compare it with a virtual model, allowing for real-time adjustments during the fabrication process to ensure precise structure formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber reinforcement is utilized to enhance structure strength, then structural integrity is improved, but system complexity increases due to the need for precise fiber placement and integration with matrix materials
Solution Approach 1:
The system segments the composite material discharge into distinct components (fibers and matrix) that are separately controlled and delivered through the print head. This allows independent optimization of fiber placement precision and matrix infiltration, managing system complexity while achieving high strength structures
Solution Approach 2:
The system incorporates sensors that provide real-time feedback on fiber placement accuracy and material deposition quality. This feedback loop enables dynamic adjustment of printing parameters to maintain structural integrity while managing the complexity of coordinating multiple material streams
2Manufacturing precision
If real-time monitoring and comparison with virtual models is implemented, then manufacturing precision is improved, but device complexity increases due to additional sensors and processing requirements
Solution Approach 1:
The system uses sensors to continuously monitor the fabricated structure and compares real-time data with the virtual model. This feedback mechanism enables automatic correction of deviations, achieving high manufacturing precision while the integration of monitoring into the existing print head minimizes additional device complexity
Solution Approach 2:
The system creates a digital twin (virtual model) of the intended structure and uses it as a reference for real-time comparison. This virtual copy enables precision control without requiring physical measurement tools for every dimension, reducing device complexity while maintaining high accuracy
Data Source
AI summary
A system is disclosed for use in additively manufacturing a structure. The system may include a print head to discharge a material, and a support to move the print head during discharging to fabricate a structure. The system may also include a receiver mounted to the print head to generate a signal indicative of at least one of a shape, a size, and a location of the discharged material, and a processor in communication with the receiver and the support. The processor may be configured to generate a data cloud of the structure fabricated by the additive manufacturing system based on the signal and based on a known position of the receiver at a time of signal generation. The processor may also be configured to make a comparison of the data cloud and a virtual model of the structure during discharging, and to selectively affect discharging based on the comparison.