Laser-Cut 3D Printer Assembly for Precise Gantry Alignment

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Solution Overview

Problem

Existing large-format three-dimensional printers are costly and suffer from lower accuracy due to extruded frames that are not properly aligned, leading to inaccuracies in printing.

Innovation Solution

Utilizing laser-cut or water-cut flat pieces of sheet metal for the frame and enclosure of the printer, ensuring precise alignment and positioning of components, eliminating the need for a separate support frame and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If extruded frame structures are used for large-format printers, then manufacturing cost is reduced, but manufacturing precision and component alignment deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoidcomponent alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The frame is divided into multiple flat sheet metal pieces instead of using a single extruded structure. Each piece is laser-cut separately with precise apertures, allowing independent manufacturing and precise assembly. This segmentation enables both cost-effectiveness through standardized fabrication and high precision through controlled joining at specific aperture locations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional mechanical extrusion process is replaced with laser cutting technology. Instead of forming three-dimensional extruded frames that are difficult to align, flat sheet pieces are laser-cut with precisely positioned apertures, substituting a complex mechanical forming process with a more controllable thermal cutting process that achieves higher precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If separate support frames and enclosures are used, then structural stability is improved, but device complexity increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidframe structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The support frame structure and the enclosure are merged into a single integrated sheet metal assembly. The same laser-cut flat pieces that form the structural frame also serve as the enclosure walls, eliminating the need for separate support frames and reducing the number of components. This integration maintains structural stability while significantly simplifying the overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flat sheet metal pieces serve multiple functions simultaneously: they provide structural support, form the enclosure, and contain precisely positioned apertures for component mounting. This multi-functionality eliminates the need for separate dedicated support structures, reducing device complexity while maintaining structural integrity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If laser-cut flat sheet metal is used for the frame, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecomponent positioningVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The manufacturing approach changes from mechanical extrusion to laser cutting, altering the key parameter of material removal precision. Laser cutting enables extremely precise control of cut width and aperture positioning, achieving component placement accuracy within ±0.0005 inch. This parameter change allows high precision manufacturing while maintaining cost-effectiveness through standardized fabrication processes.

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

Achieves high accuracy and cost-effectiveness in large-scale printing with precise component placement, enhancing the overall printing precision and eliminating the need for a separate frame structure.

Implementation Method 1

flat pieces of sheet metal, which are each laser or water cut to create apertures used to secure components of the printer

Methodology Applied

Scientific EffectLaser cutting: Laser Ablation

Implementation Method 2

flat pieces of sheet metal, which are each laser or water cut to create apertures

Methodology Applied

Scientific EffectWater jet cutting: Jet Erosion

Data Source

PatentUS12533847B2Systems, methods, and assemblies for a three-dimensional printer

Publication Date: 2026.01.27 HEARD JASON

AI summary

Assembly for three-dimensional or additive printers are disclosed comprising a base and various sidewalls. Critically, the pieces forming the assembly and the internal structure are each formed from a single, flat piece of material that is cut with water or a laser to create the desired shape and form a set of apertures at precise locations. Various components of the printer can be attached using the apertures to ensure they are positioned at precise locations within the assembly. This includes, for example, a main gantry assembly and a carriage assembly, as well as the components that permit their movement and support them within the assembly.