5-DOF FDM Printer Rotating Platform Hollow Geometries
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Solution Overview
Problem
Conventional FDM printers lack the capability to print complex geometries with hollow structures without support structures, leading to increased post-processing time and risk of damage during support removal.
Innovation Solution
An FDM printer with five degree-of-freedom motion, incorporating three translational drive elements for X, Y, and Z-axis movement and two rotational drive elements for Y-axis and combined X/Z-axis rotation, allowing continuous printing of complex geometries without external support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional FDM printers use linear translation only (3 DOF), then the device complexity is low, but the manufacturing capability is limited and cannot print complex hollow geometries without support structures
Solution Approach 1:
The patent applies dynamics by transitioning from static linear translation to dynamic multi-axis movement. The workpiece platform is made movable through two rotational drive devices, allowing it to rotate during the printing process. This dynamic capability enables the print head to access complex geometries and hollow structures from multiple angles without requiring support structures, directly resolving the contradiction between printing capability and device complexity.
Solution Approach 2:
The patent implements another dimension by adding rotational degrees of freedom to the traditional three-axis linear translation system. The two rotational drive devices introduce angular dimensions to the printing process, transforming the motion from purely linear (3 DOF) to five-degree-of-freedom movement. This dimensional expansion allows the print head to reach enclosed and hollow geometries that are inaccessible to conventional linear-only systems.
2Adaptability or versatility
If support structures are used for complex geometries, then the manufacturing capability is improved, but post-processing time increases and damage risk increases
Solution Approach 1:
The patent applies preliminary action by enabling the workpiece platform to rotate during the printing process itself, allowing the print head to access overhangs and enclosed geometries from optimal angles as they are being printed. This preliminary rotational adjustment eliminates the need for support structures that would otherwise be required, thereby preventing the need for subsequent post-processing to remove these supports and reducing both time and damage risk.
3Adaptability or versatility
If support structures are used for hollow structures, then the printing capability is improved, but the risk of damage during support removal increases
Solution Approach 1:
The patent applies dynamics by making the workpiece platform rotatable during printing, enabling the print head to access enclosed hollow geometries from multiple angles without requiring support structures. This dynamic multi-axis capability allows the formation of hollow structures that are self-supported, eliminating the need for external supports that could cause damage during removal and thereby improving workpiece integrity and reliability.
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
Enables the direct printing of complex, closed, hollow geometries in a single continuous process, reducing post-processing time and minimizing damage risks by eliminating the need for support structures.
Implementation Method 1
a filament of a certain material that is wound on a spool is fed into a heated nozzle, where the filament material becomes molten
Implementation Method 2
the filament material becomes molten and is extruded from the nozzle in a controlled manner to build up the workpiece in a layer-by-layer manner
Data Source
AI summary
An FDM printer that provides five degree-of-freedom printing capabilities. In one embodiment, the FDM printer includes three transitional drive devices that allow a printer print head to be translationally moved in the X, Y and Z axes planes and a pair of rotationally drive devices that allow a workpiece platform to be rotated in the Y-axis plane and the combined X-axis and Z-axis planes. In this manner, the relative position between the print head and the workpiece platform allows the printer to print complex workpieces in a single continuous print, such as workpieces including large closed, hollow geometries, and without the need for providing support structures for overhangs and the like.