Additive Manufacturing Segmented Build Space

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Solution Overview

Problem

Conventional additive manufacturing methods for three-dimensional objects are inefficient due to large non-productive times, making the process cost-intensive and time-consuming. Additionally, existing systems require additional space to accommodate the coating unit outside the build space during irradiation.

Innovation Solution

A method and system for additive manufacturing that subdivides the build space into segments, allowing the coating unit to move continuously while applying and solidifying layers of build-up material. This minimizes non-productive times by optimizing the use of irradiation units and reducing the need for additional space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a strictly serial sequence of applying a new layer of build-up material and irradiating it to solidify the applied layer is used, then the additive manufacturing process can be completed, but very large non-productive times occur which reduce overall efficiency

Engineering Contradiction:

Improveoverall efficiencyVSAvoidnon-productive times

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The build space is divided into multiple segments along the extension direction of the build platform. Each segment is assigned to a specific irradiation unit, allowing parallel processing of different segments. The coating unit applies build-up material continuously across segments while irradiation units simultaneously solidify material in different segments, eliminating the strictly serial sequence and reducing non-productive times.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coating unit moves continuously through all segments applying build-up material without stopping, while irradiation units continuously solidify material in their assigned segments. This continuous operation eliminates idle times between layer application and irradiation, maintaining useful action throughout the entire build process.

Inventive Principle:

Principle #20Continuity of useful action

2Ease of operation

If additional space is provided to accommodate the coating unit outside the build space during irradiation, then the coating unit can be positioned for selective solidification, but the system requires more space and increases complexity

Engineering Contradiction:

Improvecoating unit positioningVSAvoidbuild space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The build space is segmented along the extension direction, with each segment assigned to a specific irradiation unit. The coating unit moves continuously through these segments, applying material while irradiation units simultaneously process previous segments. This eliminates the need for additional external space to accommodate the coating unit during irradiation, as the segmented architecture allows overlapping operations within the build space.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a single-zone serial process to a multi-segment parallel process by adding the dimension of spatial segmentation along the build platform extension. This allows the coating unit and irradiation units to operate in different segments simultaneously, eliminating the need for the coating unit to move outside the build space while maintaining ease of operation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If the coating unit stops to accommodate irradiation completion, then irradiation can be completed properly, but non-productive times increase and efficiency decreases

Engineering Contradiction:

Improveirradiation completionVSAvoidprocess efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The build space is divided into segments with dedicated irradiation units for each segment. This allows irradiation to be completed reliably in each segment independently while the coating unit continues moving through other segments, eliminating the need to stop for irradiation completion while maintaining process reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coating unit applies build-up material to future segments in advance before those segments are ready for irradiation. Irradiation units process segments that have already received material, creating a pipeline where material application and irradiation are staggered but continuous, ensuring irradiation completion without stopping the coating unit.

Inventive Principle:

Principle #10Preliminary action

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 method significantly reduces process time and costs by minimizing non-productive times and optimizing system utilization, while maintaining consistent quality in the production of three-dimensional objects.

Implementation Method 1

at least one irradiation unit for locally selective solidification of the build-up material in the building plane

Methodology Applied

Scientific EffectSelective solidification through irradiation: Photopolymerisation

Data Source

PatentUS12220871B2Method for additive manufacture, and system

Publication Date: 2025.02.11 AMCM GMBH

AI summary

A method for the additive manufacture of at least one three-dimensional object by means of a system, wherein a coating unit is moved onward through any number of segments and/or subsegments such that the coating unit performs at least one idle run. A system for the additive manufacture of three-dimensional objects, and a computer-readable storage medium are also disclosed.