Concurrent 3D Printing With Automatic Failed-Object Replacement
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Solution Overview
Problem
Conventional 3D printing systems face issues with print failures leading to discarded prints and reduced automation due to the need for human monitoring, as a single object failure can disrupt the entire print process, affecting the quality and quantity of concurrently printed objects.
Innovation Solution
A system that stores candidate print-bed locations for each object, detects failures, pauses printing, identifies new locations, modifies print code, and resumes printing with replacement objects to ensure the desired number of objects is produced despite failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple objects are printed concurrently on the same print-bed, then productivity increases, but reliability decreases because a single object failure can disrupt the entire print process
Solution Approach 1:
The system segments the printing process by assigning each object its own dedicated print-bed location and G-code instructions. When a failure is detected in one object, the system can isolate and remove only the G-code for that specific object while preserving the G-code for other objects, allowing successful objects to continue printing without disruption.
Solution Approach 2:
The system implements continuous monitoring of the printing process with automatic failure detection. When a printing failure is detected for a specific object, the system provides feedback by automatically removing the problematic object's G-code instructions and adjusting the print plan, enabling the printing process to adapt and continue successfully.
2Productivity
If printing continues after detecting a failure, then productivity is maintained, but manufacturing precision deteriorates due to potential disruption of other objects
Solution Approach 1:
The system extracts and removes only the G-code instructions corresponding to the failed object from the overall print sequence. This selective removal prevents the failed object from potentially disrupting other objects while maintaining the integrity and precision of the remaining successful prints.
3Manufacturing precision
If human experts monitor printing to prevent errors, then manufacturing precision is improved, but extent of automation decreases and time is lost
Solution Approach 1:
The system implements self-service automation where the printing system automatically detects failures, identifies the failed object, removes its G-code instructions, and continues printing successful objects without human intervention. This automated self-correction maintains manufacturing precision while maximizing automation and eliminating manual monitoring time.
Solution Approach 2:
The system continuously monitors printing status and provides automatic feedback responses to detected failures, enabling autonomous error correction and maintaining high manufacturing precision through automated detection and response mechanisms.
Data Source
AI summary
Three-dimensionally (3D) printing a plurality of objects by storing a set of candidate print-bed locations for each object of a plurality of objects, initializing printing of each object of the plurality of objects, detecting a printing failure for a first object of the plurality of objects, pausing the printing of the first object, identifying a first print-bed location for a new object from the set of candidate print bed locations, modifying print code adding instructions to print the new object at the first print-bed location, and printing the new object at the first print-bed location.