Deformable Deposition Plane for Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing technologies face challenges in producing large, structurally complex objects due to material shrinkage, which generates tension stresses leading to deformation or breakage.

Innovation Solution

A deposition plane with a topologically deformable work surface and a handling device featuring actuators that can locally deform and move the surface to accommodate material shrinkage, thereby reducing mechanical stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If additive manufacturing is used to produce large objects, then the size of manufactured objects is increased, but material shrinkage generates tension stresses that cause deformation or breakage

Engineering Contradiction:

Improvesize of manufactured objectsVSAvoidstructural integrity of objects

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The deposition plane is made dynamically deformable through actuators that can adjust the surface topology in real-time during the additive manufacturing process. This allows the plane to adapt to and compensate for material shrinkage as it occurs, preventing stress accumulation that would lead to deformation or breakage in large objects.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the physical parameters of the deposition plane by locally deforming its surface topology. The actuators modify the position and shape of the work surface to follow the material shrinkage, thereby maintaining optimal deposition conditions and reducing mechanical stresses throughout the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If material is extruded and cooled to create object layers, then the object structure is formed, but natural shrinkage occurs causing tension stresses between layers

Engineering Contradiction:

Improvelayer structure accuracyVSAvoidtension stresses in layers

Core Design Contradiction:

Manufacturing precisionVSStress or pressure

Solution Approach 1:

The system performs preliminary action by proactively deforming the deposition plane surface before and during material deposition. The actuators anticipate and follow the expected material shrinkage, adjusting the surface topology in advance to prevent stress accumulation rather than reacting after deformation occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the harmful effect of material shrinkage into a beneficial process by using the shrinkage information to guide surface deformation. The deposition plane actively follows the material shrinkage pattern, transforming what would be a source of stress and deformation into a controlled adaptation that maintains layer accuracy and structural integrity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Device complexity

If a fixed rigid deposition plane is used, then device simplicity is maintained, but it cannot accommodate material shrinkage in large objects

Engineering Contradiction:

Improvedeposition plane structureVSAvoidability to follow material shrinkage

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The deposition plane transitions from a static rigid structure to a dynamic system with adjustable topology. Actuators are integrated into the plane structure, enabling it to deform and adapt its surface shape in response to material shrinkage, thereby achieving both adaptability and maintaining reasonable device complexity through controlled actuation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The deposition plane employs a flexible work surface that can be locally deformed by actuators. This flexible structure allows the plane to accommodate material shrinkage by changing its topology, providing the necessary adaptability while maintaining a relatively simple overall device architecture compared to fully rigid alternative systems.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The solution allows for the production of high-quality, structurally solid objects of various sizes by adapting the deposition plane to follow material shrinkage, minimizing stress and preventing deformation or breakage.

Implementation Method 1

The handling device comprises at least one actuator coupled to the work surface at the at least one deformation zone and is configured to deform it locally

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

During the cooling of the material, or following its extrusion, its natural tendency to shrink occurs, which causes tension stresses within the layers themselves

Methodology Applied

Scientific EffectThermal Contraction: Thermal Contraction

Data Source

PatentUS20250065564A1Deposition plane for additive manufacturing processes

Publication Date: 2025.02.27 EXGINEERING SA

AI summary

A deposition plane for additive manufacturing processes comprises a work surface (2) and a handling device. The work surface (2) is topologically deformable in at least one deformation zone and has a first face (2a) on which an object can be formed. The handling device comprises at least one actuator (3) coupled to a second face (2b) of the work surface (2) at the at least one deformation zone. Such a handling device is configured to locally deform the work surface (2) by moving the deformation zone thereof, preferably by exerting a pulling or pushing action on said deformation zone by means of the actuator (3).