Additive Manufacturing Structures With Vernier Alignment Markers
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Solution Overview
Problem
Conventional methods for additively manufacturing electronics require time-consuming and costly quality control for job-on-job precision, which cannot be verified during the printing process, and do not allow for easy adjustments.
Innovation Solution
A vernier-based position marker is used to indicate the relative offset between sub-bodies in the manufacturing process, enabling precise determination of displacements, rotations, and combined movements using optical or electrical detection methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional printing methods are used to additively manufacture electronics, then manufacturing capability is achieved, but quality control becomes time-consuming and costly
Solution Approach 1:
The patent applies preliminary action by incorporating position markers and alignment features during the initial printing of the first partial body, rather than verifying alignment after completion. This allows quality control to be performed before the time-consuming post-printing CT scans are required, enabling real-time detection and correction of positioning errors.
Solution Approach 2:
The patent implements feedback mechanisms through position markers that provide visual and measurable information about alignment status during the printing process. This feedback loop allows operators to monitor job-on-job precision continuously and make real-time adjustments, eliminating the need for delayed post-printing verification.
2Adaptability or versatility
If printing is interrupted for component mounting, then components can be added to the structure, but precision for subsequent printing becomes difficult to maintain
Solution Approach 1:
The patent applies preliminary action by pre-printing position markers and alignment features on the first partial body before interruption. These pre-established reference points ensure that when printing resumes after component mounting, the second partial body can be precisely aligned with the first, maintaining manufacturing precision despite the interruption.
Solution Approach 2:
The patent uses position markers as intermediary elements that mediate between the first and second partial bodies. These markers serve as reference references that ensure precise alignment during the resumption of printing, acting as a bridge that maintains coordination between interrupted printing segments.
3Measurement precision
If CT scans are used for quality control, then verification of precision is achieved, but cost and time increase significantly
Solution Approach 1:
The patent employs simple, inexpensive position markers and alignment features instead of expensive CT scanning. These disposable-like markers provide sufficient measurement precision for quality control at a fraction of the cost and time, eliminating the need for costly post-printing verification procedures.
Solution Approach 2:
The patent substitutes complex mechanical imaging systems (CT scans) with simpler optical or electrical detection methods. The position markers can be read using basic optical sensors or visual inspection, replacing the expensive and time-consuming CT scanning process while maintaining adequate measurement precision.
4Reliability
If conventional printing methods are used, then manufacturing is achieved, but real-time quality assurance is not possible
Solution Approach 1:
The patent ensures continuity of useful action by integrating quality control features directly into the printing process itself. Position markers are printed continuously alongside the partial bodies, enabling uninterrupted monitoring of alignment and precision throughout the manufacturing process, rather than requiring separate verification steps.
Solution Approach 2:
The patent implements continuous feedback through position markers that provide real-time information about alignment status during printing. This feedback enables immediate detection and correction of positioning errors, ensuring quality assurance is maintained throughout the entire manufacturing process rather than being verified only after completion.
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
Enables quick and easy 100% quality assurance of job-on-job precision, allowing for real-time adjustments and reducing the need for costly post-printing quality control, thereby improving manufacturing efficiency and accuracy.
Implementation Method 1
The vernier-based position marker is configured to indicate a relative offset between the first sub-body and the second sub-body
Implementation Method 2
enabling precise determination of displacements, rotations, and combined movements using optical or electrical detection methods
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
A structure comprises: several subbodies (10, 20) and a vernier-based position marker (30). The several subbodies (10, 20) comprise a first subbody (10), a second subbody (20), and at least one electronic component (15). The second subbody (20) is at least partially additively manufactured on the first subbody (10). The vernier-based position marker (30) is configured to indicate a relative offset between the first subbody (10) and the second subbody (20).