Large Format 3D Printing via Robot Repositioning and Tracking
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Solution Overview
Problem
Current large format 3D printing technologies are limited by the size of industrial robots, leading to high costs and complexity, and require assembling smaller printed units, which can affect accuracy and increase complexity.
Innovation Solution
A method and apparatus using six-dimensional tracking techniques with industrial robots to break down components into smaller, less expensive units that can be repositioned, allowing for unlimited size prints by mathematically combining their coordinate systems into a global coordinate system, enabling accurate and cost-effective large format 3D printing and scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If very large industrial robots are used for large format 3D printing, then the print size capability is improved, but the cost and system complexity increase exponentially
Solution Approach 1:
The system divides the large format printing task into multiple smaller print jobs that can be executed by a standard-sized robot. The build space is segmented into multiple build volumes, and the robot sequentially prints different sections or layers across the large area by repositioning the build plate or robot base between jobs, eliminating the need for a single oversized robot system
Solution Approach 2:
The system employs dynamic repositioning of either the robot base or build plate between print jobs to expand the effective print volume. The robot can be relocated to different positions around the workspace, and coordinate systems are mathematically transformed to maintain accuracy across multiple positions, effectively creating an unlimited print volume with a compact robot
2Length of stationary object
If the final printed object is divided into smaller units, then the print size limitation is overcome, but the need for fastening units together increases complexity and affects accuracy
Solution Approach 1:
The system incorporates tracking systems (such as optical or magnetic trackers) that continuously monitor the position and orientation of the build plate or robot base during repositioning. This feedback is used to update coordinate transformations in real-time, compensating for positioning errors and maintaining high accuracy across the entire large format print without requiring manual alignment or fastening of separate units
Solution Approach 2:
The system replaces mechanical alignment and fastening methods with mathematical coordinate transformations. Instead of physically joining separate printed units with adhesives or welds, the system uses software-based coordinate system transformations to seamlessly stitch together prints from multiple build volumes, eliminating mechanical joining complexity and improving accuracy
3Manufacturing precision
If higher accuracy robot arms are used to improve print head position accuracy, then the accuracy of the final printed object is improved, but the cost and complexity of the robotic printing system increase
Solution Approach 1:
The system introduces tracking devices (optical trackers, magnetic sensors, or vision systems) as intermediaries between the robot and the control system. These trackers monitor the actual position of the robot and build plate, providing feedback that enables real-time compensation for positioning errors through coordinate transformations, allowing the use of lower-cost robots while maintaining high print accuracy
Solution Approach 2:
The system replaces the need for high-precision mechanical robot arms with a combination of standard-precision robots and software-based coordinate transformations. Instead of relying on expensive high-accuracy mechanics, the system uses mathematical models and tracking feedback to achieve the required print head position accuracy, significantly reducing system cost and complexity
Data Source
AI summary
The disclosure is directed at a system, apparatus and method for 3D printing an object using an industrial robot; such object is larger and may be more accurate than the print volume and accuracy of the industrial robot that is performing the print. The system is further capable of scanning the irregular 3D surface of the printing platform in which to create the 3D object and adapt the toolpath to print on this surface. The system is further capable of scanning the 3D surface of a specimen that is larger than the print volume of the industrial robot and make a scaled copy larger or smaller. The system is also capable of monitoring the quality of the object being printed while the print is in process.