Autonomous Component Ejection via Embedded Linear Springs

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Solution Overview

Problem

Current additive manufacturing technologies face challenges in achieving high-volume production and autonomous actuation of additively manufactured components, particularly in efficiently removing components from the build platform without additional hardware.

Innovation Solution

The integration of a deposition head as a robotic manipulator to embed and release mechanical energy through linear springs, allowing for the autonomous deployment of components off the build platform, and the embedding of additional dimensions of information or functionality into components during the 3D-printing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual removal of components from build platform is used, then device complexity is low, but productivity is limited

Engineering Contradiction:

Improvethroughput of additively manufactured componentsVSAvoidhardware complexity for component removal

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The manufactured component itself serves as the actuator by incorporating a linear spring mechanism that automatically ejects the component from the build platform when activated, eliminating the need for separate ejection hardware. The component uses its own structural elements (spring, activation mechanism) to perform the removal function.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The deposition head serves multiple functions: it deposits material during manufacturing and also acts as an activation mechanism for the spring-based ejection system. This multi-functionality reduces the need for additional dedicated ejection hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If additional hardware is added for automated component removal, then productivity increases, but device complexity increases

Engineering Contradiction:

Improveautomated removal of componentsVSAvoidadditional hardware for actuation

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The linear spring mechanism is integrated directly into the manufactured component, allowing the component to self-eject without requiring external actuation hardware. The spring stores mechanical energy during manufacturing and releases it to eject the component autonomously.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The ejection mechanism is merged with the component structure itself rather than being a separate system. The linear spring and activation mechanism are fabricated as part of the component during the additive manufacturing process, combining the component and actuator into a single integrated unit.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If embedding additional dimensions of information into components is implemented, then adaptability increases, but manufacturing precision requirements increase

Engineering Contradiction:

Improvefunctionalities embedded in componentsVSAvoidprecision of embedded information

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The additive manufacturing process parameters (temperature, deposition rate, layer thickness) are precisely controlled to ensure accurate formation of embedded functional features. By optimizing these parameters, the system achieves high manufacturing precision while embedding multiple dimensions of information and functionality into the components.

Inventive Principle:

Principle #35Parameter changes

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 approach significantly increases the throughput of additively manufactured components by enabling automated removal and embedding additional functionalities, allowing for dynamic interaction and expanded design parameters without requiring physical modifications to the manufacturing machines.

Implementation Method 1

an actuator tool that stores and releases mechanical energy through linear springs

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

converts feedstock in the form of a filament, for example of polylactic acid (PLA), into a three-dimensional component by melting the filament and depositing it in built-up layers

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS12233604B1Augmented manufacturing by embedding autonomous interactions between manufactured components and manufacturing machines

Publication Date: 2025.02.25 UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATOR NAT AERONAUTICS & SPACE ADMINISTRATION

AI summary

Augmenting the functionality of an off-the-shelf additive manufacturing machine, such as a 3D printer, by generating a component design having an autonomy characteristic, and that may impart a functionality to one or more components manufactured by the additive manufacturing machine that is based on an interaction between the component and the additive manufacturing machine. The design includes code for instructing the additive machine to build an ancillary component, such as a cantilever spring, and build the primary manufactured object, and use the cantilever spring to propel the object off the build platform. In this manner the functionality of an off-the-shelf additive manufacturing machine is expanded without physical modification of the machine, and can be implemented remotely to embed additional functionality into designed components that are to be fabricated, for example on spacecraft where physical retrofits are impractical. Other applications include parts and material testing and rapid prototyping.