Continuous 3D Printing Support Structure Gripper
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Solution Overview
Problem
Conventional three-dimensional printing methods are labor-intensive and time-consuming when manufacturing large numbers of objects, as they require multiple batches and separate jobs due to volume limitations in the build well, restricting the number of objects that can be produced efficiently.
Innovation Solution
A method and apparatus that allow for continuous manufacturing of objects by forming a support structure within the build region, using grippers to translate and bind layers of manufacturing medium, enabling the creation of a series of objects surrounded by support structures that can be progressively lowered and recycled, allowing for the continuous addition of new layers and removal of completed objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional three-dimensional printing methods are used to manufacture a large number of objects, then the number of objects that can be manufactured is limited by the volume of the build well, but the manufacturing process becomes labor-intensive and time-consuming due to multiple batches and separate jobs
Solution Approach 1:
The support structure is segmented into multiple batches, with each batch containing a subset of objects. This allows the build well volume to be efficiently utilized by dividing the total object set into manageable groups that can be manufactured simultaneously, thereby increasing the number of objects produced per manufacturing run without compromising manufacturing speed
Solution Approach 2:
Multiple objects are nested within a single support structure that acts as a container. The support structure envelops multiple objects during the manufacturing process, allowing them to be produced together in one batch. After manufacturing, the support structure is removed to release the individual objects, enabling high-volume production within the constrained build well volume
2Quantity of substance
If the build well volume is increased to manufacture more objects simultaneously, then the number of objects per batch increases, but the apparatus complexity and manufacturing cost increase
Solution Approach 1:
The support structure is designed with dynamic characteristics that allow it to be selectively bound during manufacturing and then released after manufacturing. The binding strength is controlled to enable easy removal, and the support structure can be regenerated for subsequent batches. This dynamic approach allows the same apparatus to handle large numbers of objects without requiring permanent expansion of the build well volume
Solution Approach 2:
The support structure is temporarily created to enable manufacturing of multiple objects, then discarded after serving its purpose. The materials from the discarded support structure are recovered and reused to create new support structures for subsequent batches. This approach allows high-volume manufacturing without permanently increasing apparatus complexity or build well size
3Manufacturing precision
If objects are manufactured one at a time in separate jobs, then each object can be manufactured with high precision, but the overall manufacturing time and labor intensity increase significantly
Solution Approach 1:
Multiple objects that would traditionally be manufactured separately are merged into a single manufacturing job by enclosing them together within one support structure. The support structure allows all objects to be manufactured simultaneously in the build well, maintaining individual object precision while dramatically reducing total manufacturing time and eliminating the need for multiple setup and removal operations
Data Source
AI summary
A method, of manufacturing a series of objects is disclosed. In the method, a layer of a manufacturing medium is provided. Portions of the layer of the medium, are bond together at at least edge regions of the layer to form a support portion. The support portion is lowered while gripping the support portion by the edge regions of the layer. A further layer of the medium is provided supported by the support portion. Portions of the further layer of the medium are selectively bound to form at least an object portion. An apparatus for performing the method is also disclosed.