Automated 3D Build Conveyor for Continuous Fabrication

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Solution Overview

Problem

Current three-dimensional prototyping devices require frequent user intervention to retrieve completed objects, hindering continuous fabrication of multiple objects, especially in low-cost devices intended for hobbyists and home users.

Innovation Solution

An automated conveyor system that supports multiple sequential builds, allowing for automatic removal of fabricated objects and restoration of the build surface, utilizing a heated/cooled, treated surface for adhesion and separation, and integrated with a three-dimensional printer for continuous operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a three-dimensional prototyping device is used to fabricate objects, then manufacturing precision and accuracy are improved, but user intervention is required frequently to retrieve completed objects, reducing productivity

Engineering Contradiction:

Improvefabrication accuracyVSAvoidcontinuous fabrication capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The build surface is segmented into multiple distinct regions (first build surface and second build surface) that can be independently used. While one surface is being used for fabrication, another surface can prepare or hold completed objects, enabling continuous operation without waiting for object removal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by preparing the second build surface in advance (with different surface properties for easier release) while the first build surface is still in use. This allows seamless transition between builds without interruption for surface preparation.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If the build surface is designed for strong adhesion to hold objects during fabrication, then manufacturing precision is improved, but object removal becomes difficult, requiring user intervention and reducing productivity

Engineering Contradiction:

Improveobject adhesion during buildVSAvoidobject removal ease

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Different regions of the build system have different surface properties optimized for their specific functions. The first build surface has properties optimized for fabrication adhesion, while the second build surface has properties optimized for easy object release. This local differentiation resolves the contradiction between holding objects during build and removing them afterward.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of designing a single build surface that must balance both strong adhesion and easy release, the system inverts the approach by creating two surfaces with opposite characteristics. One surface is optimized for strong adhesion during fabrication, while the other is optimized for easy release, and they are used in sequence.

Inventive Principle:

Principle #13The other way round (Inversion)

3Device complexity

If a single build surface is used in the three-dimensional printer, then device complexity is reduced, but continuous fabrication of multiple objects cannot be achieved, requiring user intervention

Engineering Contradiction:

Improvebuild surface configurationVSAvoidcontinuous operation capability

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The build system is designed with multi-functionality by incorporating two build surfaces that can serve different purposes. The first surface is used for active fabrication, while the second surface can serve as a preparation area, holding area, or pre-heating zone, allowing the system to perform multiple functions without requiring separate devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 continuous fabrication of multiple objects without user intervention, improving efficiency and productivity in three-dimensional prototyping by automating the removal and preparation of build surfaces within the printer.

Implementation Method 1

The conveyor may be heated/cooled, coated, or otherwise treated to assist in adhesion during a build, as well as removal of objects after a build

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

The conveyor may be heated/cooled, coated, or otherwise treated to assist in adhesion during a build, as well as removal of objects after a build

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8668859B2Automated 3D build processes

Publication Date: 2014.03.11 STRATASYS INC

AI summary

A conveyor or other transport mechanism is provided to support multiple, sequential builds from a three-dimensional fabrication machine. The conveyor may be heated/cooled, coated, or otherwise treated to assist in adhesion during a build, as well as removal of objects after a build. Each fabricated object may be automatically removed from the conveyor as the conveyor moves in order to restore a buildable surface for fabrication of additional objects.