Additive Manufacturing Repositioning for Hybrid Assembly
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Solution Overview
Problem
Existing additive manufacturing methods and systems face challenges in maintaining the quality of additively manufactured articles when procedures are performed on partially completed parts, as they often require precise repositioning and resumption of printing without causing gaps or flaws in the structure.
Innovation Solution
A method and system for additive manufacturing that allows for the initiation of the process, pausing to perform procedures such as assembling premade parts, and accurately repositioning the partially completed article using features like kinetic ball mounts or pins to ensure minimal impact on the final product quality, enabling the continuation of printing around or encapsulating the assembled parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If procedures are performed on a partially completed article during additive manufacturing, then external operations can be completed, but the quality of the additively manufactured article may be adversely affected
Solution Approach 1:
The patent applies preliminary action by creating locating features and repositioning structures before the interruption occurs. The system prepares the build surface and partially completed article with integrated locating features that enable precise repositioning when printing resumes, thereby maintaining manufacturing precision while allowing external operations to be performed.
Solution Approach 2:
The patent replaces manual or crude mechanical repositioning methods with an automated optical measurement and calculation system. The system uses measurement data from the partially completed article and build surface to computationally determine precise repositioning distances and orientations, then automatically positions the article using controlled mechanical movement driven by computational algorithms.
2Ease of manufacture
If the partially completed article is removed from the build surface, then external procedures can be performed, but repositioning accuracy may be compromised
Solution Approach 1:
The patent implements feedback by measuring the actual positions of locating features on both the build surface and partially completed article, then using this measurement data to calculate the precise repositioning required. The system continuously monitors and adjusts the repositioning process based on actual measured conditions rather than relying on theoretical or preset positions.
Solution Approach 2:
The patent creates a digital replica or model of the physical locating features through optical measurement. The measurement system captures the precise geometry and position of locating features, and this digital copy is used to calculate repositioning parameters, enabling accurate reconstruction of the original positioning without physically marking or altering the components.
3Adaptability or versatility
If printing is paused to assemble premade parts, then complex structures can be created, but gaps or flaws may occur in the additive structure
Solution Approach 1:
The patent applies preliminary action by designing and preparing locating features and repositioning structures before the printing pause and external assembly operations occur. These pre-integrated features ensure that when printing resumes, the article can be accurately repositioned and the additive structure can continue without gaps or flaws, maintaining structural integrity while enabling complex multi-stage manufacturing.
Data Source
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Figure 3~4B
AI summary
A method for manufacturing an article includes initiating additive manufacturing of the article, and forming a portion of the article using an additive manufacturing process on an additive manufacturing system. The additive manufacturing process may be paused, and a procedure may be performed on the article. The additive manufacturing process may be resumed and the article completed. A system for performing additive manufacturing of an article includes a printhead, and drive modules operative to generate translational motion between the printhead and a build surface in more than one axis. A rotational joint is operative to rotate the printhead about at least one axis.