Automated 3D Print Part Cleaning via Sensor-Guided Fluid Nozzle
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Solution Overview
Problem
Current manual cleaning methods for three-dimensional object printer parts are inefficient due to vision obstruction by fluid spray, requiring multiple cycles to thoroughly remove support material from complex geometries.
Innovation Solution
An automated cleaning system that uses a controller to correlate part data with structural data to precisely direct a fluid nozzle, assisted by actuators and an optical sensor, to target and remove support material from specific areas of the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cleaning with pressurized fluid is used, then the operator can visually inspect the part, but the fluid spray obstructs vision making it difficult to direct fluid into nooks and crannies
Solution Approach 1:
The system performs preliminary actions by using sensors to detect support material locations and pre-positioning the fluid nozzle before actual cleaning begins. This allows the system to prepare a cleaning path and target areas in advance, avoiding the need for real-time visual adjustment during cleaning.
Solution Approach 2:
The patent replaces the manual mechanical system (operator vision and hand coordination) with an automated sensor-based system. Sensors detect support material locations and the controller automatically directs the fluid nozzle, substituting human visual inspection with electronic detection mechanisms.
2Reliability
If manual cleaning requires multiple cycles to thoroughly remove support material, then cleaning completeness improves, but cleaning time and productivity decrease
Solution Approach 1:
The system incorporates feedback mechanisms where sensors continuously detect support material during cleaning and the controller adjusts the fluid directing process in real-time. This feedback loop ensures thorough removal while optimizing cleaning time by immediately responding to detected support material rather than requiring multiple separate cycles.
Solution Approach 2:
The automated system maintains continuous useful action by continuously directing fluid at detected support material locations without interruption for inspection. The process runs continuously with the sensor and controller ensuring thorough cleaning in a single uninterrupted cycle, eliminating the stop-start nature of manual multi-cycle cleaning.
3Manufacturing precision
If automated fluid directing is used with reference to structural data, then cleaning precision improves, but system complexity increases
Solution Approach 1:
The controller serves multiple functions: it processes structural data, controls fluid nozzle positioning, manages fluid flow, and coordinates with sensors. By making the controller a multi-functional universal device, the system achieves high precision cleaning without proportionally increasing overall system complexity, as one component performs multiple critical roles.
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 thorough and efficient removal of support material in a single session, reducing the need for multiple cleaning cycles and improving the accuracy of support material removal.
Implementation Method 1
a pressurized source of fluid operatively connected to the fluid directing nozzle
Data Source
AI summary
A method of operating a cleaning system removes support material from parts made by a three-dimensional printer. The method operates the cleaning system to correlate data for features on a part located within a receptacle with structural data in a file used by the three-dimensional printer to fabricate the part. The method then operates one or more actuators to locate a fluid directing nozzle pneumatically connected to a pressurized fluid source opposite areas containing support material and operates the pressurized fluid source to enable pressurized fluid to be directed by the fluid directing nozzle at the support material. The method includes generating image data of the cleaned areas with an image sensor so the removal of the support material can be confirmed, and if an area is not sufficiently cleaned, the cleaning operation can be repeated.