Belt Leveling in Additive Manufacturing Layer Control
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Solution Overview
Problem
Three-dimensional object printers face challenges in leveling layers to correct for height variations caused by variable material expulsion, leading to contamination issues due to the removal of excess material during the leveling process.
Innovation Solution
A three-dimensional object printing system incorporating a belt assembly with rollers, a continuous belt, and a blade to remove and transport excess material away from the object, utilizing a heated roller to reduce viscosity and a blade to scrape off the material, effectively managing height variations and minimizing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material is removed during leveling to correct height variations, then manufacturing precision is improved, but contamination of the object increases
Solution Approach 1:
A continuous belt serves as an intermediary carrier between the leveling blade and the waste container. The belt picks up excess material from the object surface, transports it away, and deposits it in a controlled location, preventing direct contact between removed material and the object, thus reducing contamination while maintaining layer height precision
Solution Approach 2:
The harmful factor (excess material causing contamination) is extracted from the object surface through the leveling blade and removed via the belt transport system. By separating the removal process from the object environment and transporting material away, the contaminating effect is eliminated while the precision benefit is retained
2Object-affected harmful factors
If a belt assembly with heating is added to transport removed material, then contamination is reduced, but device complexity increases
Solution Approach 1:
The continuous belt performs multiple functions: it acts as a transport medium for removed material, provides a heated surface to control material viscosity for easier removal and transport, and serves as a containment structure. This multi-functionality reduces the need for separate components, offsetting the added complexity with functional integration
Solution Approach 2:
The heating element changes the temperature parameter of the belt surface, which in turn changes the viscosity parameter of the material being transported. This parameter change enables controlled material flow and easier handling, making the complex belt assembly more effective and manageable
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
The system efficiently removes excess material, reducing height variations and contamination by transporting it away from the object, ensuring precise shaping and minimizing material buildup on the object's surface.
Implementation Method 1
The second roller has a heater configured to heat the second roller to a temperature high enough to reduce a viscosity of the material forming the object on the platform
Implementation Method 2
The continuous belt is entrained about the first roller and the second roller, and the actuator is operatively connected to the first roller or the second roller to drive the operatively connected roller and move the continuous belt about the first and the second roller
Data Source
AI summary
A three-dimensional object printing system improves the leveling of an object during object printing and removal of waste material during leveling. The printing system includes a material applicator configured to expel material, a member configured to move in a process direction to a position opposite the material applicator to enable the material applicator to expel material onto the member, and a belt assembly. The belt assembly includes a first roller, a second roller, and a continuous belt entrained about the first roller and the second roller. The belt assembly is configured to remove a portion of the material ejected onto the member. The belt assembly is further configured to move the removed portion of the material away from the member.