3D Printing Build Gap for Continuous Long Structure Fabrication
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Solution Overview
Problem
Conventional 3D printing systems with rectangular powder beds of limited size and depth restrict the size and length of printed structures, as they require filling the entire bed for each layer, limiting the scalability of printed parts.
Innovation Solution
A 3D printing system with a build platform featuring a build gap that allows for continuous printing, utilizing a base plate and advancement assembly to move the base plate and formed structure downward by a layer thickness after each layer is formed, enabling the use of a larger build gap and allowing for the printing of structures of greater length without the need to refill the entire bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a rectangular powder bed configuration is used with limited area and depth, then the system can maintain a simple structure and easy operation, but the size and length of printed structures are limited
Solution Approach 1:
The build platform is divided into a build gap region where powder is selectively deposited and a support region. The base plate is segmented to extend beyond the build gap, allowing continuous printing by advancing the base plate incrementally. This segmentation enables the printed structure to extend beyond the physical boundaries of the powder bed area.
Solution Approach 2:
The invention transitions from a traditional 2D powder bed configuration to a 3D continuous build gap configuration. By defining a build gap with specific depth and extending the base plate beyond the powder bed boundaries, the system adds dimensional freedom that allows structures to grow in length without being constrained by the powder bed's physical dimensions.
2Productivity
If the entire powder bed must be filled for each layer, then manufacturing precision can be maintained, but productivity decreases due to repeated filling and smoothing operations
Solution Approach 1:
The build gap is configured to allow continuous powder deposition without requiring the entire bed to be refilled for each layer. Powder is continuously supplied through the build gap as the base plate advances, eliminating idle time associated with complete bed refilling and smoothing operations. This continuous action maintains productivity while reducing unnecessary powder consumption.
Solution Approach 2:
The base plate is preliminarily positioned to extend beyond the powder bed boundaries before printing begins. This preliminary configuration establishes a continuous build surface that allows subsequent layers to be deposited without interruption, eliminating the need to refill the entire bed for each layer and thereby increasing productivity.
3Length of moving object
If a build platform with a build gap is used to enable continuous printing, then the length of printed structures can be increased, but the device complexity increases due to the advancement assembly and base plate mechanism
Solution Approach 1:
The base plate serves multiple functions: it supports the printed structure, defines the build gap boundary, and acts as the advancing element. The advancement assembly simply moves the base plate incrementally without requiring complex repositioning mechanisms. This self-service approach minimizes device complexity while enabling continuous printing of extended structures.
Solution Approach 2:
The base plate is designed as a multi-functional component that simultaneously supports the printed structure, defines the build gap geometry, and serves as the element to be advanced. The build platform integrates the build gap definition and advancement functions into a unified system, reducing overall device complexity despite the extended printing capability.
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 the fabrication of larger and longer 3D structures by allowing continuous deposition and fusion of powder layers within a larger build gap, overcoming the size limitations of traditional systems.
Implementation Method 1
At least one directed energy source is positioned above the build platform and is configured to apply directed energy to at least a portion of the build gap to form a layer of the three-dimensional structure
Implementation Method 2
The advancement assembly includes at least one advancement member which is moveable toward and away from the build platform and at least one hold member in fixed relation to the build platform. In at least one embodiment, the advancement member and the hold member are each a selectively energized magnet.
Data Source
AI summary
An apparatus and method for fabricating a three-dimensional object from a representation of the object stored in memory. The apparatus includes a build platform having a build gap defined therein. A base plate is initially supported along a lower surface of the build platform such that an edge of the base plate extends along and closes off the build gap. A powder delivery assembly is configured to supply powder to the build gap. At least one directed energy source is configured to apply directed energy to at least a portion of the build gap to form a layer of the three-dimensional structure. An advancement assembly configured to selectively engage with the base plate and/or the three-dimensional structure to hold the base plate and the three-dimensional structure in a fixed position during forming of a layer and to advance the base plate and the three-dimensional structure once the layer is formed.