Blade Support Unit for Automated Additive Manufacturing Replacement
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Solution Overview
Problem
Existing build material application devices for additive manufacturing require frequent manual replacement of worn blade-like members, disrupting the manufacturing process and involving cumbersome positional calibration.
Innovation Solution
A build material application device with a support unit that allows for automatic or semi-automatic replacement of blade-like members, featuring moveable support unit members that switch between holding and non-holding positions to facilitate easy insertion and removal of new or worn blades, along with a shaping unit for adapting endless material into pre-defined dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual replacement of build material application members is performed, then the worn blades can be replaced, but the manufacturing process is interrupted and time-consuming calibration is required
Solution Approach 1:
The support unit is divided into multiple support unit members (first, second, third, and fourth members) that can independently move between holding and non-holding positions. This segmentation allows individual members to be positioned to either secure or release the build material application member, enabling quick replacement without manual intervention while maintaining continuous operation.
Solution Approach 2:
The replacement system is designed to automatically perform the replacement of build material application members through the coordinated movement of support unit members. The system serves itself by using automated positioning and holding mechanisms, eliminating the need for manual calibration and replacement operations, thus reducing replacement time and maintaining continuous manufacturing operation.
2Ease of manufacture
If manual replacement of build material application members is performed, then the worn blades can be replaced, but cumbersome positional calibration is required
Solution Approach 1:
The manual calibration process is replaced with an automated mechanical positioning system. The support unit members are equipped with drive units and guiding devices that automatically position the build material application member in the correct location. This substitution of manual mechanical calibration with an automated positioning system simplifies the replacement process while reducing the complexity of calibration operations.
Solution Approach 2:
The system changes the operational parameters of the support unit members by moving them between holding and non-holding positions. This parameter change (positioning state) automatically adjusts the system from a calibrated state to a replacement state and back, eliminating the need for complex manual calibration procedures while maintaining replacement simplicity.
3Productivity
If automatic replacement system is implemented, then replacement efficiency is improved, but the device complexity increases
Solution Approach 1:
The support unit members are designed with multi-functionality, serving both as structural supports and as active positioning/holding mechanisms. Each support unit member can function as a structural element, a positioning element, and a holding element depending on its position. This universality reduces the need for separate components, thereby improving replacement efficiency while limiting the increase in device complexity.
Solution Approach 2:
The guiding devices and drive units are integrated within or alongside the support unit members in a nested arrangement. The guiding devices are positioned within the structure of the support unit members, and the drive units are integrated into the same structural framework. This nesting approach allows the automatic replacement system to function efficiently while minimizing the overall device complexity by sharing structural elements.
Data Source
AI summary
Build material application device for additively manufacturing a three-dimensional object, the build material application device comprising: at least one blade-like build material application member; at least one support unit for supporting the blade-like build material application member, wherein the support unit comprises at least two support unit members defining a receiving section for receiving a blade-like build material application member, a first support unit member is moveably supported relative to a second support unit member between a first operating position, in which a holding force is exertable or exerted on a blade-like build material application member received in the receiving section, and a second operating position, in which no holding force is exertable or exerted on a blade-like build material application member received in the receiving section.