3D Concrete Bead Width Calibration for Gantry Feed Control

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Solution Overview

Problem

Current manual control methods for additive construction with cement-based materials in 3D printing lack precision in achieving dimensionally accurate bead widths, especially in varying concrete mixtures and environmental conditions, leading to inaccuracies in structural performance.

Innovation Solution

A control system that generates a process map correlating bead width to gantry velocity, allowing for precise manipulation of bead width through calibration prints and advanced scanning, enabling operators to select multiple bead widths regardless of material properties, with adjustments to pump speed and feed rate parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual control methods are used for pump speed and gantry velocity, then ease of operation is maintained, but manufacturing precision of bead width deteriorates

Engineering Contradiction:

Improvemanual controlVSAvoidbead width accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system implements feedback control by measuring the actual bead width after deposition and using this measurement to automatically adjust pump speed and gantry velocity for subsequent beads. This closed-loop feedback mechanism eliminates the need for manual control while ensuring precise bead width accuracy, directly resolving the contradiction between ease of operation and manufacturing precision.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual mechanical control systems with an automated control system that uses sensors to measure bead width and computer-controlled actuators to adjust pump speed and gantry velocity. This substitution of mechanical manual control with automated sensor-based control systems achieves both ease of operation and high manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If automated control systems are implemented to improve bead width precision, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improvebead width accuracyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The control system performs self-calibration by automatically measuring its own bead width output and using this self-generated data to adjust its parameters. This self-service capability reduces the need for external calibration equipment and complex manual setup procedures, thereby improving precision while limiting the increase in device complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system achieves precise bead width control by dynamically changing operational parameters (pump speed, gantry velocity) based on measured bead width. This parameter-based control approach is more straightforward than redesigning the entire mechanical system, thus improving precision with minimal increase in device complexity.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If calibration prints are performed to generate process maps for bead width control, then manufacturing precision improves, but loss of time occurs during calibration

Engineering Contradiction:

Improvebead width control accuracyVSAvoidcalibration time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs calibration prints and generates process maps before actual production printing. This preliminary action establishes the relationship between operational parameters and bead width in advance, allowing for precise control during production without repeated calibration interruptions, thus minimizing time loss while maintaining high precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Once the process map is generated through calibration, the system continuously applies this knowledge to control bead width throughout production printing. This continuity eliminates the need for frequent recalibration, maintaining high manufacturing precision while minimizing time loss to calibration activities.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS20250103024A1Bead width manipulation and control for additive construction operations

Publication Date: 2025.03.27 UNITED STATES OF AMERICA THE AS REPRESENTED BY THE SEC OF THE ARMY

AI summary

In one embodiment, an additive construction method includes printing a calibration print out of a cement-based material using a 3D printer having a pump to pump the cement-based material and having a gantry operating at a gantry feed rate under control of an additive manufacturing software to dispense the cement-based material; measuring a bead width along a length of the calibration print; performing curve fitting on bead width measurements of the bead width to produce a calibration print process map that correlates the bead width of the calibration print to the gantry feed rate of the 3D printer to provide a calibration print correlation; and, if all of one or more desired bead widths for an additive construction print fall within the range of bead widths of the calibration print process map, using the calibration print correlation to modify bead width parameters of the additive manufacturing software for operating the 3D printer to perform bead width manipulation for the additive construction print.