Additive Manufacturing System With Removable Print Surface

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Solution Overview

Problem

Existing additive manufacturing systems face challenges in accurately positioning and repositioning partially fabricated objects during multiple processing steps, leading to poor object quality and waste due to exposure to undesired processing parameters, and with increasing system size, operational zones become obstructed, complicating the manufacturing process.

Innovation Solution

A system comprising a pedestal, a motion platform, a print head, and an enclosure that allows for precise movement and positioning of the print head within a defined build volume, with a removable print surface and integrated service stations for easy access and processing, enabling accurate and repeatable fabrication without compromising operational zone clearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If additive manufacturing systems increase in size to manufacture larger parts, then build volume is improved, but operational zone clearance deteriorates due to obstructions from larger gantries and robotic arms

Engineering Contradiction:

Improvebuild volumeVSAvoidoperational zone clearance

Core Design Contradiction:

Volume of stationary objectVSEase of operation

Solution Approach 1:

The system divides the additive manufacturing process into multiple processing steps performed at separate processing stations. The object is moved between stations rather than having all operations performed by a single large system, allowing each station to be compact while the overall system handles large parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A single object can be processed through multiple processing stations that perform different operations (additive manufacturing, heat treatment, machining, etc.). Each station is designed to handle the same object type but perform different functions, eliminating the need for oversized single-purpose equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple processing steps are used to manufacture objects, then manufacturing capability is improved, but positioning accuracy deteriorates when moving objects between processing stations

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidpositioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system performs preliminary positioning actions at each processing station before the actual processing step. Locating features are pre-configured on the object and corresponding positioning mechanisms are prepared at each station to ensure accurate repositioning before manufacturing or treatment operations begin.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback mechanisms to monitor and adjust object positioning between processing stations. Sensors and control systems track the object's location and make real-time adjustments to ensure it is correctly positioned for each subsequent processing step, compensating for any positioning errors.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20240042690A1Additive manufacturing system

Publication Date: 2024.02.08 CONTINUOUS COMPOSITES INC

AI summary

A system is disclosed for additively manufacturing a structure. The system may have a pedestal, a motion platform mounted to the pedestal, and a print head coupled to the motion platform. The system may also include an enclosure at least partially surrounding the motion platform and the print head, and a print surface configured to selectively dock with the pedestal.