Auto Tip Calibration in Extrusion Apparatus
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Solution Overview
Problem
Existing three-dimensional modeling machines require manual and time-consuming calibration of extrusion tips, which can be unreliable and difficult for inexperienced users, leading to inaccuracies and failures in model construction.
Innovation Solution
An automatic calibration method that generates a material build profile, determines its relative position, compares it to an expected profile, and adjusts the deposition device to achieve precise positioning of extrusion tips in the X, Y, and Z directions, eliminating the need for operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual calibration method is used, then device complexity is reduced, but measurement precision and manufacturing precision deteriorate
Solution Approach 1:
The calibration system performs self-calibration automatically without requiring manual intervention. The controller executes calibration routines that autonomously determine tip-to-substrate offsets, tip-to-tip offsets, and other positioning parameters by analyzing deposited material profiles and sensor feedback, thereby achieving high precision without increasing operational complexity for the user.
Solution Approach 2:
The patent replaces manual mechanical measurement and adjustment methods with automated computational algorithms and sensor-based detection. The system uses digital image processing, sensor feedback, and controller calculations to determine calibration parameters, substituting the need for manual calipers, rulers, and visual estimation with automated electronic measurement systems.
2Manufacturing precision
If automatic calibration method is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The calibration system is integrated into the existing extrusion apparatus architecture, utilizing the same controller, sensor system, and material deposition mechanisms for both manufacturing and calibration functions. This multi-functionality approach allows the system to perform calibration without adding separate dedicated hardware, thereby improving precision while minimizing the increase in overall device complexity.
Solution Approach 2:
The system performs calibration routines automatically before or during the manufacturing process, establishing accurate tip positioning parameters in advance. By conducting calibration as a preliminary or concurrent operation rather than a separate post-processing step, the system achieves high precision positioning without requiring complex additional calibration equipment or procedures.
3Ease of operation
If manual calibration is performed, then ease of operation is improved, but productivity deteriorates
Solution Approach 1:
The calibration system automatically performs all calibration measurements and adjustments without requiring user intervention. The controller executes calibration routines that autonomously analyze deposited material profiles, calculate offset values, and update positioning parameters, thereby reducing calibration time while maintaining ease of operation through automated execution.
Solution Approach 2:
The calibration process is integrated into the continuous operation of the extrusion system, allowing calibration to be performed during idle periods, between prints, or as part of the normal manufacturing cycle. This continuous integration eliminates downtime dedicated to separate calibration operations, improving productivity while keeping the system accessible and easy to operate.
4Loss of time
If manual calibration is used, then loss of time is reduced, but reliability deteriorates
Solution Approach 1:
The patent replaces manual visual estimation and physical measurement with automated optical sensors, digital image processing, and computational algorithms. This substitution eliminates human error, ensures consistent and repeatable measurements, and achieves higher reliability in calibration accuracy while maintaining or reducing calibration time through automated execution.
Solution Approach 2:
The calibration system incorporates sensor feedback loops that continuously monitor the deposited material profiles and adjust calibration parameters accordingly. By analyzing actual material deposition characteristics and using this feedback to refine positioning parameters, the system achieves reliable and accurate calibration results while completing the process efficiently.
Data Source
AI summary
The present invention is a method for performing a calibration routine of a deposition device in a three-dimensional modeling machine that deposits a material to build up three-dimensional objects as directed by a controller on a substrate mounted on a platform. The method comprises generating a material build profile, which represents a three-dimensional structure at defined locations. A relative position of the material build profile is then determined. An expected build profile is identified and then compared to the determined relative position of the material build profile to identify any difference which represents an offset. The modeling system then positions the deposition device based upon the offset.