Automated Insert Placement in 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D rapid prototyping and manufacturing systems face inefficiencies and accuracy issues when manually inserting embedded components, such as bolts, into 3D objects during the build process, which affects the precision and throughput of the manufacturing process.
Innovation Solution
A system and method that incorporates a robotic arm or telescoping arm integrated with the extrusion head, capable of receiving build sequence data to accurately place inserts within the 3D object layers, allowing for precise and automated embedding of inserts during the layer-based additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual insert insertion is used during build operations, then flexibility in handling different inserts is maintained, but build efficiency is reduced and placement accuracy deteriorates
Solution Approach 1:
The system enables self-service automation where the rapid prototyping system automatically handles insert placement without requiring manual human intervention. The automated mechanism retrieves inserts from a magazine and places them precisely in predetermined locations during the build process, allowing the system to service itself rather than requiring operator involvement for each insert placement.
Solution Approach 2:
The patent replaces the manual mechanical insertion process with an automated mechanical system. A robotic arm or automated placement mechanism substitutes for human hands, using controlled mechanical motion to deliver inserts to their predetermined positions. This substitution eliminates manual operation while maintaining the mechanical precision needed for accurate insert placement.
2Adaptability or versatility
If manual insert insertion is used during build operations, then adaptability to different insert types is maintained, but placement accuracy deteriorates
Solution Approach 1:
The system performs preliminary actions by pre-programming the automated mechanism with precise location data for each insert based on the CAD model. Before the build process begins, the system calculates and stores the exact coordinates, orientations, and timing for each insert placement. This preliminary preparation ensures that when inserts are placed during building, they achieve high precision without requiring manual adjustment.
Solution Approach 2:
The automated insert placement system incorporates feedback mechanisms that monitor the build process in real-time. The system uses sensors and position data to verify that inserts are placed at the correct locations and orientations, allowing for automatic correction or adjustment. This feedback loop ensures high placement accuracy while maintaining adaptability to different insert types through programmable control.
3Productivity
If automated insert placement is implemented, then build efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the insert placement function with the existing rapid prototyping system architecture. The automated mechanism is integrated into the build chamber, combining the extrusion head, support structure formation, and insert placement into a unified system. By merging these functions rather than adding separate independent systems, the patent improves build efficiency while minimizing the increase in overall device complexity.
Solution Approach 2:
The automated mechanism is designed with multi-functionality to handle various insert types and placement scenarios through a single integrated system. The same mechanism can place different types of inserts (fasteners, structural components, electronic elements) by adjusting programmable parameters. This universality allows the system to maintain high build efficiency across diverse applications without requiring multiple specialized devices, thereby limiting the increase in complexity.
4Manufacturing precision
If automated insert placement is implemented, then placement accuracy is improved, but device complexity increases
Solution Approach 1:
The system achieves high placement accuracy through preliminary action by pre-calculating and pre-programming the exact positions, orientations, and timing for each insert based on the CAD model. The automated mechanism uses this pre-programmed data to execute precise placements without requiring complex real-time decision-making or adjustment mechanisms. This approach improves accuracy while keeping the control system relatively simple.
Solution Approach 2:
The patent introduces an intermediary software layer that mediates between the CAD model and the physical placement mechanism. This intermediary translates the high-level design data into precise motion commands for the automated mechanism, handling the complexity of coordinate transformations and timing synchronization. By using this intermediary software layer, the hardware can remain relatively simple while achieving high placement accuracy through intelligent software control.
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
This solution enhances the accuracy and reduces delays in the deposition sequence, maintaining the throughput of the system by allowing for precise placement of inserts within the 3D objects, reducing the need for manual intervention and minimizing the risk of errors, while also preheating inserts to prevent thermal distortion.
Implementation Method 1
For deposition-based systems (e.g., fused deposition modeling and ink jetting), the build path defines the pattern for depositing roads of build material from a moveable deposition head to form the given layer.
Implementation Method 2
an insert placement apparatus in signal communication with the controller, and configured to place at least one insert in the plurality of formed layers based on the build sequence data
Implementation Method 3
The extruded build material fuses to previously deposited build material, and solidifies upon a drop in temperature.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A system (10, 110, 210) for building a three-dimensional object (26, 126, 226) with a layer-based additive technique, the system (10, 110, 210) comprising a controller (16, 116, 216) configured to receive build sequence data for the three-dimensional object (26, 126, 226), a head assembly (18, 118, 218) in signal communication with the controller (16, 116, 216) and configured to form a plurality of layers (44, 304) of the three-dimensional object (26, 126, 226) based on the build sequence data, and an insert placement apparatus (22, 164, 280) in signal communication with the controller (16, 116, 216) and configured to place at least one insert (38, 138, 298) in the plurality of formed layers (44, 304) based on the build sequence data.