Additive Manufacturing Fiducial Positioning Probe
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Solution Overview
Problem
Additive manufacturing systems face challenges in printing large or elongated 3D items, as existing technologies struggle to accurately position and support such items within the limited build volume, leading to inaccuracies and difficulties in moving heavy, long parts.
Innovation Solution
The system employs a location sensing probe with finer resolution than the print head, combined with a drive system for indexing a print foundation and print head, allowing for extended printing volumes and the use of support structures and fiducial markers to stabilize and accurately position long 3D items during printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a support structure is used to support overhanging portions of 3D items, then the item can be fabricated with complex geometries, but the support structure itself requires additional material and printing time
Solution Approach 1:
The support structure is designed with predetermined removal features and strategic placement that enables automatic or facilitated removal after printing. The support structure includes features such as breakaway connections and hierarchical arrangements that allow for efficient removal without requiring extensive manual intervention, thus reducing the time loss associated with support removal while maintaining the ability to fabricate complex geometries
2Volume of moving object
If the build volume is extended to print larger items, then items larger than the chamber can be printed, but positioning accuracy deteriorates due to increased distance from reference points
Solution Approach 1:
The build space is segmented into multiple zones with distributed fiducial markers placed throughout the extended build volume. Rather than relying on a single reference point, the system divides the large build space into smaller measurement zones, each with its own fiducial reference. This segmentation allows the probe to maintain accurate positioning by frequently referencing local fiducials rather than traveling long distances from a single origin point
Solution Approach 2:
Fiducial markers serve as intermediary reference objects placed within the extended build volume. These fiducials act as intermediate reference points that the probe can use to establish accurate positioning without needing to measure from the original origin point. The fiducials mediate between the probe and the distant features being measured, enabling accurate positioning throughout the extended build space
3Manufacturing precision
If fiducial markers are placed throughout the build space, then positioning accuracy is improved, but the complexity of the system increases due to additional markers and probe operations
Solution Approach 1:
The fiducial markers are designed to serve multiple functions simultaneously: they provide positioning references for the probe, serve as alignment features for the print head, and act as verification points for build accuracy. This multi-functionality reduces the need for separate reference systems, thereby limiting the increase in system complexity while maintaining improved positioning accuracy throughout the extended build volume
Data Source
AI summary
A probe for an additive manufacturing system includes a probe body having a first air port therethrough between an inlet and an outlet, and a location sensing probe extending from the probe body. The location sensing probe includes a probe end and a probe bar, the probe bar coupled between the probe body and the probe end, and a channel surrounding the probe bar, the channel having an inner tube having an inlet proximate the probe body and an outlet proximate the probe end. A method of determining a position of an item being printed in an additive manufacturing system, includes probing the position with a location sensing probe having a resolution finer than a print resolution of the print head.