3D Printing System Using Continuous Carrier Sheet Motion

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Solution Overview

Problem

Current 3D printing technologies face inefficiencies due to the discontinuous, sequential nature of layer-by-layer additive processes, leading to increased downtime, mechanical limitations, and reduced productivity, primarily caused by back-and-forth motion and the need for complex, heavy actuators.

Innovation Solution

The implementation of a 3D printing system that uses lightweight carrier sheets to continuously deposit 2D layers, allowing for continuous motion in one direction, reducing the need for back-and-forth motion and enabling simultaneous deposition and transfer phases, thereby increasing speed and precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If layer-by-layer additive approach is used to create 3D parts, then manufacturing precision is improved, but productivity deteriorates due to discontinuous sequential processing

Engineering Contradiction:

Improve3D part geometry precisionVSAvoidpart fabrication throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent implements continuous motion of the carrier sheet through the printing system, eliminating the stop-and-go nature of traditional layer-by-layer additive manufacturing. The carrier sheet continuously transports material layers through the build zone, allowing uninterrupted deposition and significantly improving manufacturing throughput while maintaining precision through controlled continuous motion.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent segments the manufacturing process into independent continuous stages: material deposition on moving carrier sheets, curing zones, and transfer mechanisms. This segmentation allows each stage to operate continuously at optimal speed without waiting for other stages, resolving the productivity bottleneck while maintaining quality through specialized zone optimization.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If back-and-forth motion is used for layer deposition, then manufacturing precision is improved through controlled positioning, but device complexity worsens due to need for heavy actuators

Engineering Contradiction:

Improvelayer deposition accuracyVSAvoidactuator system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of moving the deposition head back and forth over a stationary build platform, the patent inverts the approach by moving the carrier sheet continuously through a stationary deposition system. This eliminates the need for complex heavy actuators to position the deposition head, while precision is maintained through controlled carrier sheet motion and fixed positioning of the deposition apparatus.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces complex mechanical positioning systems with a continuous motion system where the carrier sheet transports material through the build zone. This substitution eliminates the need for heavy actuators and complex mechanical positioning mechanisms, reducing device complexity while maintaining deposition accuracy through controlled continuous transport.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If continuous motion in one direction is implemented, then productivity is improved through reduced downtime, but manufacturing precision may worsen due to motion control challenges

Engineering Contradiction:

Improvemanufacturing speedVSAvoidlayer deposition accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements feedback control systems that monitor carrier sheet position, speed, and material deposition parameters in real-time. This feedback enables dynamic adjustment of deposition parameters to compensate for motion variations, maintaining manufacturing precision despite continuous high-speed motion and eliminating the trade-off between speed and accuracy.

Inventive Principle:

Principle #23Feedback

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 manufacturing speed, reduces mechanical complexity and weight, and improves precision by allowing continuous deposition and transfer of layers without the need for heavy actuators, leading to more efficient and cost-effective 3D part construction.

Implementation Method 1

depositing a second toner layer on top of the first toner layer using electrophotography

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS11738503B2Constructing 3-dimensional parts using electrophotography

Publication Date: 2023.08.29 XEROX CORP

AI summary

Systems and methods for constructing 3-dimensional (3D) parts are disclosed. A printing system may include a deposition system configured to print a plurality of 2-dimensional (2D) layers onto a plurality of carrier sheets. The printing system also includes a transferring system configured to transfer a 2D layer from a carrier sheet of the plurality of carrier sheets, onto the 3D part. The 3D part may be located on a base substrate. The printing system further includes a feed system configured to provide the plurality of carrier sheets from the deposition system to the transfer system in a successive fashion while maintaining the directionality of printing in the deposition and transferring systems.