Near-Net-Shape Additive Manufacturing with Integrated Print-and-Trim Gantry

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Solution Overview

Problem

Conventional additive manufacturing machines with separate printing and trimming gantries are costly and unsuitable for smaller machines, increasing machine size and complexity, and the process of melting thin filaments for 3D printing is slow for large items.

Innovation Solution

A single-gantry machine design that integrates both printing and trimming operations, allowing for near net shape additive manufacturing, with a fixed gantry and movable work table, and a print head and trim head that operate independently or as a unit, supporting both horizontal and vertical printing configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate printing and trimming gantries are used in additive manufacturing machines, then printing and trimming operations can be performed independently, but machine size and complexity increase, making it costly and unsuitable for smaller machines

Engineering Contradiction:

Improvemanufacturing costVSAvoidmachine structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the printing head and trim head onto a single gantry system, allowing both operations to be performed from one structure. This merging eliminates the need for separate gantries, reducing machine size and complexity while maintaining the capability to perform both printing and trimming operations independently.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single gantry is designed to support multiple functions by mounting both the print head and trim head on the same structure. This universal design allows the gantry to perform printing, trimming, and potentially other operations, reducing the overall number of components needed and lowering manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If a single-gantry design integrating printing and trimming is used, then machine size and costs are reduced, but the coordination and control of multiple operations from one gantry becomes more complex

Engineering Contradiction:

Improvemachine structureVSAvoidoperation control

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The system dynamically switches between printing and trimming operations by controlling which head is active at any given time. The single gantry can move the print head for deposition operations and the trim head for finishing operations, with the control system managing the transitions between these different operational modes seamlessly.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The integrated system automatically coordinates between the print head and trim head operations, with the control system managing the sequence of operations without requiring manual intervention. The machine serves itself by automatically transitioning between printing and trimming based on the manufacturing process requirements.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If thin filament melting process is used for 3D printing, then material can be deposited layer by layer, but the process is slow for producing large items

Engineering Contradiction:

Improvelayer deposition accuracyVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The manufacturing process is segmented into two distinct phases: a rapid near-net-shape printing phase that creates the bulk of the component quickly, followed by a precision trimming phase that achieves the final dimensional accuracy. This segmentation allows each phase to be optimized independently for its specific goal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The near-net-shape component is preliminarily formed using faster deposition methods before the final precision trimming is applied. This preliminary action creates a close approximation of the final part, reducing the amount of material that needs to be removed and speeding up the overall production process while maintaining final precision.

Inventive Principle:

Principle #10Preliminary action

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

The integrated machine reduces costs and space requirements while enabling efficient production of large components by combining printing and trimming processes, enhancing production speed and flexibility.

Implementation Method 1

a process of melting a thin layer of thermoplastic material, and applying this material in layers to produce a final part

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

The heated material may be applied to the existing structure in thin layers, melting and fusing with the existing material to produce a solid finished product

Methodology Applied

Scientific EffectFusion: Welding

Implementation Method 3

Friction from the rotating screw, combined with heat from the barrel, may soften the plastic

Methodology Applied

Scientific EffectFriction heating: Friction

Data Source

PatentUS12420475B2Near net shape additive manufacturing apparatus

Publication Date: 2025.09.23 THERMWOOD CORP

AI summary

An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.