Additive Extrusion Printing with Real-Time Dimensional Measurement
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Solution Overview
Problem
Manufactured objects often fail to meet design requirements due to size inaccuracies, leading to significant losses and delayed product delivery, as existing methods do not allow for real-time measurement and adjustment during the manufacturing process.
Innovation Solution
An integrated system that combines additive extrusion printing with real-time measurement using a coordinate measuring machine, allowing for on-the-fly adjustments of extrusion parameters such as trajectory, velocity, and dimension to ensure dimensional accuracy during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If measurement is performed after manufacturing, then dimensional accuracy can be verified, but time loss and productivity are reduced due to post-manufacturing inspection and potential rework
Solution Approach 1:
The system performs measurement during the manufacturing process rather than after completion, allowing dimensional verification to occur before the entire object is finished. This preliminary measurement action enables early detection of dimensional deviations and prevents wasting time completing objects that will ultimately fail inspection.
Solution Approach 2:
The system implements real-time feedback by continuously measuring the object during manufacturing and using this measurement data to adjust manufacturing parameters on-the-fly. This closed-loop feedback mechanism ensures dimensional accuracy is maintained throughout the process rather than discovered only after completion.
2Productivity
If measurement and adjustment are performed during manufacturing, then productivity is improved by reducing waste and rework, but device complexity increases due to integration of measurement and manufacturing systems
Solution Approach 1:
The system merges the manufacturing device with measurement capabilities into an integrated system. The manufacturing apparatus incorporates measurement tools and control systems that work together in unison, allowing simultaneous manufacturing and measurement operations without requiring separate equipment.
Solution Approach 2:
The integrated system performs multiple functions simultaneously - it can manufacture objects while concurrently measuring their dimensions and adjusting parameters. This multi-functionality eliminates the need for separate manufacturing and inspection equipment, improving productivity without proportionally increasing device complexity.
3Manufacturing precision
If real-time measurement and adjustment are implemented, then manufacturing precision is improved through continuous monitoring, but loss of substance increases due to material waste from discarded defective objects
Solution Approach 1:
The system performs measurement during the manufacturing process to detect dimensional deviations early, before the entire object is completed. This preliminary detection allows for early termination of manufacturing for defective objects, preventing waste of additional material that would be consumed if the object were completed before inspection.
Solution Approach 2:
Real-time measurement feedback enables immediate detection of dimensional deviations and triggers adjustment of manufacturing parameters or termination of the process. This prevents continuation of manufacturing on defective objects, thereby reducing material waste while maintaining precision through continuous monitoring.
Data Source
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AI summary
A method of producing a three-dimensional object from an extrusion of material forms uses a movable portion of an additive extrusion printing device to form at least one line of material ("line of material"). The printing device preferably extrudes the material as a function of a nominal model having a specification of the object. The method also measures, using a coordinate measuring machine, at least one dimension of the line of material after starting to extrude the line of material. During or after measuring, the method checks, using a checker operatively coupled with the coordinate measuring machine, the dimensional accuracy of at least one dimension of the line of material by comparing the at least one dimension with at least one specification of the nominal model of the object.