Extended Structure Additive Manufacturing Device
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Solution Overview
Problem
Current additive manufacturing techniques are limited by the size of their build volume, preventing the creation of large continuous parts without dividing them into subparts and connecting them post-production, which restricts the complexity and scale of objects that can be manufactured.
Innovation Solution
An extended structure additive manufacturing device with a movable material bonding component and positioning system that allows the device to move relative to the part being created, enabling the production of parts larger than the device's build volume by using propulsion mechanisms such as thrusters, arms, rollers, and worm gears to extend the part beyond the device's boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the build volume of the additive manufacturing device is increased to produce larger parts, then the size of manufacturable parts is improved, but the device size and complexity increase significantly
Solution Approach 1:
The patent divides the additive manufacturing process into multiple segments: a compact build volume device produces subparts, which are then assembled into a larger final structure. This segmentation allows the device to remain small while the final product exceeds the build volume limitation.
Solution Approach 2:
The patent transitions from producing a single large part within the build volume to producing multiple subparts that are assembled in a different spatial arrangement. The final structure extends beyond the original build volume boundaries through dimensional reconfiguration.
2Length of stationary object
If additive manufacturing devices are made larger to accommodate bigger parts, then the maximum part size is improved, but the device becomes impractically large for certain applications
Solution Approach 1:
The manufacturing system is segmented into a portable device that creates smaller subparts and an external assembly process. This allows the device to remain operationally simple and portable while still achieving large-scale production through multiple build cycles and assembly.
3Device complexity
If the build volume is limited, then the device remains compact and manageable, but large continuous parts cannot be produced without dividing them into subparts
Solution Approach 1:
The patent accepts the build volume limitation and segments the final product into multiple subparts manufactured sequentially. Connection features are integrated into each subpart during manufacturing, enabling automated or manual assembly into a continuous large-scale structure.
Solution Approach 2:
Connection features are preliminarily integrated into each subpart during the additive manufacturing process itself, rather than adding them afterward. This preliminary action simplifies the subsequent assembly process and maintains ease of manufacture for the overall system.
Data Source
AI summary
An extended structure additive manufacturing device and method are provided. The device includes a movable material bonding component and a movement mechanism which enable the device to create parts outside the conventional additive manufacturing device print volumes defined by the device and its print-head. Methods of making parts involve creating a portion of a part and moving the extended structure additive manufacturing device relative to the part and printing a second portion of the part. Parts incapable of being formed using a conventional additive manufacturing device may be made using the extended structure additive manufacturing device and/or methods disclosed herein.