Floating Frame Motion Isolation for 3D Printers

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Solution Overview

Problem

Standard gantry 3D printers face limitations in achieving faster print speeds due to oscillating forces causing warping and deflections, which are typically addressed by using heavier and stiffer gantries, resulting in higher costs and reduced print quality.

Innovation Solution

A motion isolation apparatus and method utilizing a floating frame with greater stiffness than the structural frame to elastically deflect and dampen oscillating forces, maintaining alignment between the 3D printhead and print surface, and incorporating electro-mechanical actuators for precise movements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If faster print speeds are achieved by accelerating the 3D printhead, then productivity increases, but oscillating forces cause deflections and warping of the 3D model

Engineering Contradiction:

Improveprint speedVSAvoidmodel accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent converts the harmful oscillating forces generated by fast-moving printheads into beneficial elastic deflections of the structural frame. By designing the frame with controlled flexibility, the oscillating forces cause the frame to deform elastically, which dampens the vibrations and prevents warping of the printed model. This allows high-speed printing without sacrificing accuracy.

Inventive Principle:

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

Solution Approach 2:

The patent changes the mechanical parameters of the gantry system by transitioning from a rigid gantry to a flexible structural frame with optimized stiffness characteristics. The frame is designed with specific moment of inertia and elastic properties that allow it to absorb and dampen oscillating forces at high printing speeds, enabling both high productivity and high precision simultaneously.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If heavier and stiffer gantries are used to reduce deflections, then manufacturing precision improves, but device complexity and cost increase

Engineering Contradiction:

Improvemodel accuracyVSAvoidgantry structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent optimizes the stiffness parameters of the structural frame to achieve the minimum required rigidity for precision printing. Rather than using excessively heavy and stiff gantries, the frame is designed with controlled flexibility that provides sufficient stiffness to prevent warping while maintaining a simpler, lighter structure. This reduces device complexity and cost while preserving manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If heavier and stiffer gantries are used to counter oscillating forces, then manufacturing precision improves, but weight increases

Engineering Contradiction:

Improvemodel accuracyVSAvoidgantry weight

Core Design Contradiction:

Manufacturing precisionVSWeight of stationary object

Solution Approach 1:

The patent optimizes the weight and stiffness parameters of the structural frame to achieve the minimum necessary rigidity for precision printing. The frame is designed with controlled elastic properties that allow it to dampen oscillating forces effectively without requiring excessive weight. This reduces the stationary object weight while maintaining manufacturing precision through optimized structural parameters rather than brute-force reinforcement.

Inventive Principle:

Principle #35Parameter changes

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 faster print speeds and higher quality prints with reduced warping, while reducing the weight and cost of the 3D printing system, allowing for more versatile installations and improved mechanical vibrations analysis.

Implementation Method 1

the structural frame elastically deflects to dampen oscillating forces applied to the floating frame by the 3D printhead during printing

Methodology Applied

Scientific EffectElastic deflection: Elasticity

Implementation Method 2

the structural frame elastically deflects to dampen oscillating forces

Methodology Applied

Scientific EffectVibration damping: Damping

Data Source

PatentUS12179428B2Motion isolation apparatus, methods, and systems

Publication Date: 2024.12.31 PANTHEON DESIGN LTD

AI summary

Motion isolation apparatus, methods, and systems are disclosed. One example is a motion isolation apparatus comprising a floating frame that maintains an alignment between a 3D printhead and a 3D print surface, the floating frame having a floating frame stiffness; and a structural frame that supports the floating frame and has a structural frame stiffness, the floating frame stiffness being greater than the structural frame stiffness so that the structural frame elastically deflects to dampen oscillating forces applied to the floating frame by the 3D printhead during printing without disrupting the alignment. Related apparatus, methods, and systems also are disclosed.