Continuous 3D Printing With Folding Build Plates
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Solution Overview
Problem
Conventional 3D printing processes operate in batch mode, leading to time losses during reset processes and limitations on the size of manufactured parts due to the size of the printing chamber, resulting in weak seams when parts are assembled in sections.
Innovation Solution
A continuous 3D printing system utilizing a collapsible build plate that unfolds to provide a horizontal surface within a printing chamber, allowing for the production of large, seamless parts along the vertical axis without interruptions for resets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional batch mode 3D printing is used, then the printing chamber size limits the maximum part size, but using multiple sections to accommodate large parts creates weak seams during assembly
Solution Approach 1:
The build plate is segmented into multiple sections that can be independently positioned. During printing, sections are arranged to provide a continuous horizontal surface. After printing, sections can be reconfigured to facilitate easy removal of the completed part without creating weak seams, as the part is printed as a single continuous piece rather than assembled sections.
Solution Approach 2:
The build plate sections are made dynamically reconfigurable, transitioning from a fixed configuration during printing to a movable configuration during part removal. The sections can be moved independently to create clearance for part removal while maintaining a stable horizontal surface during the printing process, eliminating the need for weak seams in assembled parts.
2Productivity
If conventional batch mode 3D printing is used, then the printing process can be completed, but time losses occur during reset processes between batches
Solution Approach 1:
While one build plate is undergoing the printing process, other build plates are being prepared in advance with support structures and horizontal surfaces. This overlapping of operations eliminates idle reset time between batches, as the system continuously performs useful actions across multiple build plates in sequence, maintaining uninterrupted productivity.
Solution Approach 2:
Build plates are prepared in advance before the printing cycle begins. Support structures are pre-positioned and horizontal surfaces are pre-established on subsequent build plates while the current print job is in progress. This preliminary preparation eliminates the need for time-consuming reset operations between batches, as everything is ready for the next immediate printing cycle.
3Ease of operation
If a fixed horizontal build plate is used, then printing can proceed smoothly, but the build plate cannot be removed or reconfigured during the printing process
Solution Approach 1:
The build plate is divided into multiple independent sections that can be individually reconfigured. During printing, sections remain stable to ensure printing reliability. After printing completes, sections can be independently moved or removed to facilitate part extraction, providing operational flexibility without compromising printing stability.
Solution Approach 2:
The build plate system transitions from a static configuration during printing to a dynamic reconfigurable state after printing. Sections are locked in place during the printing process to maintain stability and reliability, then become movable after printing completes, allowing easy removal and reconfiguration for the next batch without affecting printing quality.
Data Source
AI summary
A method of 3D printing, a 3D printing system, and a vertical conveyor are disclosed herein. The 3D printing system comprises a vertical conveyor having a plurality of folding build plates; a plurality of biasing devices, a biasing device being configured to rotate a folding build plate from a folded position to a substantially horizontal position when the folding build plate enters a printing chamber position, and a 3D print head inside the print chamber adapted to 3D print an object on the folding build plate in the substantially horizontal position.