Articulated 3D Printing Plane for Support-Free Large Parts

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Solution Overview

Problem

Conventional 3D printing systems face limitations in building large parts due to the need for additional support material, which increases cost and complexity, and expanding printer build volume is costly and inefficient.

Innovation Solution

A 3D printer with a gantry and articulated extruder assembly that allows for a variable print angle, enabling the printing of parts with overhangs or hollow sections without or with reduced support material, by rotating the printing plane relative to the horizontal surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional 3D printing with horizontal layers is used, then the printing process is simple, but support material is required for overhanging layers increasing complexity and cost

Engineering Contradiction:

Improveprinting process simplicityVSAvoidsupport material requirement

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies dynamics by making the printing plane angle variable rather than fixed. The extruder assembly can articulate to change the print angle dynamically during the printing process, allowing the system to adapt to different geometries and eliminate support material requirements while maintaining manufacturing simplicity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the parameter of print angle from a fixed zero-degree horizontal orientation to a variable angle that can be adjusted during printing. This parameter change allows layers to be deposited at optimal angles for specific geometries, eliminating the need for support material while keeping the manufacturing process straightforward.

Inventive Principle:

Principle #35Parameter changes

2Volume of stationary object

If printer build volume is expanded to accommodate larger parts, then larger parts can be printed, but the cost increases significantly

Engineering Contradiction:

Improvebuild volumeVSAvoidprinting cost

Core Design Contradiction:

Volume of stationary objectVSEase of manufacture

Solution Approach 1:

The patent uses dynamic angle adjustment to print large parts that extend beyond the printer's physical build volume. By articulating the extruder assembly and changing layer angles, the system can deposit material at orientations that allow parts to grow larger than the stationary build chamber would normally permit, avoiding costly hardware expansions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent adds angular dimensionality to the printing process by allowing layers to be deposited at various angles relative to the build plate. This dimensional change enables the printing of oversized parts without expanding the physical build volume, as layers can extend beyond the horizontal boundaries of the printer through angular orientation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Volume of stationary object

If parts are split into separate pieces for printing, then the part size limitation is overcome, but alignment and joining complexity increases

Engineering Contradiction:

Improvepart size capabilityVSAvoidjoining process complexity

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The patent applies dynamics by enabling continuous printing of large parts through angular adjustment rather than static horizontal layering. This dynamic capability eliminates the need to split parts into multiple pieces, as the articulated extruder can deposit layers at angles that allow uninterrupted printing of oversized components, avoiding alignment and joining complexities.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If vertical printing orientation is used, then support material is minimized, but printing time increases due to layer cooling requirements

Engineering Contradiction:

Improvesupport material amountVSAvoidprinting throughput

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent changes the print angle parameter dynamically based on the specific geometry being printed. For overhanging features, it uses angled layers to eliminate support material, while for vertical sections, it can use near-vertical orientations to minimize cooling time requirements. This parameter optimization balances support material reduction with printing throughput enhancement.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses dynamic angle adjustment to optimize each layer's orientation based on the current geometry being printed. This allows the system to switch between angles that minimize support material and angles that optimize cooling time, thereby balancing both support material reduction and printing productivity rather than being constrained to a single fixed orientation.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12502824B2Non-orthogonal additive manufacturing and the treatment of parts manufactured thereof

Publication Date: 2025.12.23 UNIVERSITY OF MAINE

AI summary

The present disclosure provides a 3D printer including a receiving surface for accepting the accumulation of material layers, and a gantry having a shaft and carriage that is translated along the shaft, and an extruder assembly that is articulated to rotate a printing plane, wherein the extruder assembly is attached to the carriage and the articulated extruder assembly is manipulated to rotate the printing plane away from parallel with the receiving surface.