Continuous 3D Printing via Angled Build Platform Conveyor
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Solution Overview
Problem
Existing 3D printing technologies face challenges in achieving high-throughput production due to the complexity and inefficiency of horizontal build surfaces, which require frequent vertical adjustments and high user supervision, limiting their ability to produce multiple objects quickly and simultaneously.
Innovation Solution
A 3D printing system that continuously moves the build platform along an angled pathway, allowing for incremental layer addition at multiple positions, reducing the need for vertical adjustments and enabling simultaneous production of multiple objects at different stages of completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a horizontal build surface is used in 3D printing, then the build surface is convenient to engineer and simplifies printing design, but it requires frequent vertical adjustments along the z-axis and increases device complexity
Solution Approach 1:
Instead of moving the build surface vertically (conventional approach), the patent inverts the approach by keeping the build surface stationary and moving the material supply and processing components horizontally relative to it. This eliminates the need for complex vertical adjustment mechanisms while maintaining the ability to add successive layers.
Solution Approach 2:
The patent segments the printing process into multiple stationary build surfaces arranged horizontally, where each surface can work independently on different objects or different stages of the same object. This allows parallel processing and eliminates the need for a single build surface to perform all vertical movements.
2Manufacturing precision
If a horizontal build surface with vertical adjustment is used, then layer-by-layer printing is enabled, but it increases the time to form each 3D object due to settling time requirements
Solution Approach 1:
The patent implements continuous horizontal movement of the material supply and processing components relative to the stationary build surface, eliminating idle settling time between layers. The process continues without interruption as materials are continuously fed and processed into successive layers, maintaining constant productive action.
Solution Approach 2:
The patent prepares materials in advance and positions them for continuous feeding into the build zone before actual layer formation begins. This preliminary preparation ensures that materials are ready for immediate processing, eliminating waiting time and maintaining continuous production flow.
3Ease of operation
If a stationary horizontal build surface is used, then the printing process is simple to operate, but it severely limits high-throughput production capability
Solution Approach 1:
The patent transitions from conventional vertical layer-by-layer building to horizontal continuous production. By moving the process in the horizontal dimension rather than vertically, multiple objects can be produced simultaneously or in rapid succession, dramatically increasing throughput while keeping the build surface stationary and simple to operate.
Solution Approach 2:
The patent introduces dynamic horizontal movement of material supply and processing components while keeping the build surface static. This dynamic approach in the horizontal dimension enables continuous production and high throughput, contrasting with the static vertical approach of conventional printers.
4Quantity of substance
If multiple objects are built simultaneously on a carousel system, then production volume increases, but all objects must be at the same layer stage and the entire set must be completely printed before a new set can begin
Solution Approach 1:
The patent segments the production process into multiple independent stationary build surfaces, each capable of working on different objects or different stages simultaneously. This segmentation allows parallel processing of multiple objects at different completion stages, eliminating the synchronization constraint of carousel systems.
Solution Approach 2:
The patent uses preliminary action by having multiple build surfaces prepare different objects at different stages simultaneously. While one surface completes an object, another surface is already preparing the next object, creating a continuous pipeline of production that maximizes throughput without requiring synchronized layer completion.
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
This approach enhances production efficiency by allowing for continuous, high-throughput manufacturing with minimal user intervention, as multiple objects can be printed successively without the need for synchronized layer completion, significantly reducing production time and increasing output.
Implementation Method 1
A 3D printing system that continuously moves the build platform along an angled pathway, allowing for incremental layer addition at multiple positions
Data Source
AI summary
A printer apparatus and a method for continuously printing a three-dimensional (3D) object. The printer apparatus has an elongated container for containing build fluid comprising a monomer from which the 3D object is made. A means for continuous conveying a build platform has a build surface that descending down into the build fluid. A matrix of light emitting elements are disposed above the elongated container, and emit a predetermined pattern of a reactive light toward the continuously conveyed build surface and at the upper surface of the build fluid. The reactive light has a predetermined pattern that polymerizes and/or agglomerates a portion of the upper surface of the build fluid into a build material having a build pattern comprising the build material. The build platform can have a plurality of build surface segments attached in series along a continuous conveyor.