3D Printing Kinematic Coupling for Reusable Build Platform
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing technologies face challenges in maintaining a level build platform, leading to increased costs and complexity due to the need for frequent re-leveling and material wastage, especially when the platform is moved or reinstalled.
Innovation Solution
A kinematic coupling system between the build platform and the movable stage, utilizing curved protrusions and locating features for six points of contact, along with flexures and magnetic preloading, allows for precise alignment and repeatability, enabling the build platform to be removed and repositioned without requiring further adjustments for resumed printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the build platform is removed and reinstalled, then multi-step operations can be performed on the part, but the alignment between the print head and build plate becomes substantially off requiring re-leveling
Solution Approach 1:
The patent applies preliminary action by pre-configuring the build platform with a kinematic coupling mechanism that includes three curved protrusions and six locating features. This pre-established mechanical interface ensures that when the build platform is removed and reinstalled, it automatically returns to its precise original position and orientation without requiring re-leveling operations, thus maintaining manufacturing precision while enabling multi-step operations
Solution Approach 2:
The kinematic coupling mechanism enables self-service by allowing the build platform to self-align and self-locate when reinstalled on the movable stage. The three curved protrusions on the build platform mate with six locating features on the stage, creating a self-correcting positioning system that eliminates the need for external re-leveling tools or procedures, thereby maintaining alignment precision through the platform's own structural features
2Manufacturing precision
If a disposable part is built below the actual part to absorb misalignment, then alignment mismatch is compensated, but material is wasted and print time increases
Solution Approach 1:
The patent extracts the alignment compensation function from the printed part itself by implementing a kinematic coupling mechanism on the build platform. Instead of incorporating alignment compensation features within the disposable support structure, the solution separates the positioning function into a dedicated mechanical interface between the build platform and movable stage, eliminating the need for material-wasting support structures while maintaining alignment precision
3Manufacturing precision
If the build platform is soaked up by a disposable part, then misalignment is absorbed, but print time and material costs increase
Solution Approach 1:
The patent replaces the material-based misalignment absorption approach (using disposable support parts) with a mechanical substitution approach (kinematic coupling mechanism). The mechanical interface of three curved protrusions and six locating features provides precise alignment through rigid mechanical constraints rather than consuming material layers, thereby maintaining misalignment absorption capability while eliminating the time penalty associated with printing disposable support structures
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
This solution eliminates the need for frequent re-leveling, reduces material wastage, and allows for multi-step operations on 3D printed parts, expanding the printer's functionality beyond prototype production by enabling precise alignment and efficient layer resumption.
Implementation Method 1
At least two flexures are provided. One flexure is operative with respect to each of two of the three curved protrusions attached to differentially change a Z position of at least one of the points of contact.
Implementation Method 2
A kinematic coupling is positioned between the build platform and movable stage which holds said build platform
Data Source
AI summary
A three dimensional printer incorporates a kinematic coupling between the build platform and movable stage which holds the build platform, of three curved protrusions attached to one of the build platform or the movable stage and six locating features formed in receivers of the other. At least two flexures differentially change a Z position of each of two of the curved protrusions. 3D printing is paused at a preset level of completion, and the build platform may be removed for external operations. A print resume circuit resumes printing of additional printed layers at the previous position in response to a return detection circuit that responds to an input (e.g., a touch screen confirmation).