Circular Additive Printing With Radial Frequency Control
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in achieving uniform coverage and efficient material distribution when forming patterns in circular paths, particularly due to the limitations of operating multiple additive sources at a single frequency.
Innovation Solution
A system and method where additive sources are distributed across a printing zone and actuated at frequencies proportional to their distance from the center of rotation, allowing for discrete amounts of material to be deposited on a substrate as it rotates, ensuring uniform coverage and enabling the formation of patterns with both material and open spaces within a circular printing area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all additive sources are operated at a single frequency, then the control system is simple, but the coverage uniformity deteriorates
Solution Approach 1:
The patent applies local quality by assigning different actuation frequencies to additive sources based on their radial positions. Sources closer to the center operate at lower frequencies while sources at the periphery operate at higher frequencies, optimizing material deposition for each local region's specific requirements and achieving uniform coverage across the entire circular substrate.
Solution Approach 2:
The system transitions from a static single-frequency operation to a dynamic multi-frequency operation. The actuation frequency of each additive source is dynamically adjusted according to its distance from the center of rotation, allowing the system to adapt to the varying deposition requirements at different radial positions while maintaining coordinated control.
2Manufacturing precision
If additive sources are distributed across a printing zone and actuated at different frequencies, then coverage uniformity is improved, but the control system complexity increases
Solution Approach 1:
The patent changes the operational parameter (actuation frequency) of additive sources based on their spatial position. By varying the frequency parameter according to radial distance, the system achieves uniform material coverage across different regions of the circular substrate, with each source operating at an optimized frequency for its specific location.
3Productivity
If multiple additive sources operate in parallel, then productivity is improved, but achieving uniform material distribution becomes more difficult
Solution Approach 1:
Each additive source operates with locally optimized parameters based on its position in the printing zone. Sources at different radial distances use different actuation frequencies tailored to their specific deposition requirements, ensuring that material distribution remains uniform even as multiple sources work in parallel to increase productivity.
Data Source
AI summary
A layer of additive material is formed in a circular printing area on a substrate using additive sources distributed across a printing zone. The additive sources form predetermined discrete amounts of the additive material. The substrate and the additive sources are rotated with respect to each other around a center of rotation, so that a pattern of the additive material is formed in a circular printing area on the substrate. Each additive source receives actuation waveforms at an actuation frequency that is proportional to a distance of the additive source from the center of rotation. The actuation waveforms include formation signals, with a maximum of one formation signal in each cycle of the actuation frequency. The formation signals result in the additive sources forming the predetermined discrete amounts of the additive material on the substrate.