Leveling Device Vertical Clearance for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in efficiently leveling layers, particularly when the leveling device is wider than the printing head, leading to stalling due to contact between the leveling device and imperfections on the topmost surface of the layer.
Innovation Solution
A method and system where the vertical distance between a portion of a layer and the leveling device is increased before dispensing the building material for the next portion, ensuring that the leveling device does not contact the solidified surface, thereby preventing stalling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the leveling device is made wider than the printing head to level the entire layer, then the layer leveling quality is improved, but the device contacts imperfections on the solidified surface causing stalling
Solution Approach 1:
The layer formation process is divided into multiple segments or portions. The printing head deposits material in discrete portions along the indexing direction, and the leveling device processes each portion sequentially as it is deposited, rather than attempting to level the entire layer at once. This segmentation allows the leveling device to work on fresh, non-solidified material only.
Solution Approach 2:
The leveling action is performed preliminarily on each portion immediately after material deposition, before the material solidifies and creates surface imperfections. By leveling each portion in place right after it is deposited, the system prevents the formation of problematic surface features before they can interfere with subsequent leveling operations.
2Area of stationary object
If the leveling device processes the entire layer at once, then the leveling coverage is improved, but contact with solidified surface imperfections causes process stalling
Solution Approach 1:
The leveling device maintains continuous operation by processing material in a continuous flow as it is deposited by the printing head. The indexing mechanism moves the layer incrementally, allowing the leveling device to continuously level fresh portions without interruption or stalling, ensuring uninterrupted productive operation.
Solution Approach 2:
The layer is divided into multiple portions that are deposited and leveled sequentially. This segmentation approach allows the leveling device to cover the entire layer area through repeated sequential passes on different portions, rather than requiring simultaneous processing of the entire layer at once.
3Reliability
If the vertical distance between the layer and leveling device is increased to prevent contact, then stalling is prevented, but the leveling effectiveness on solidified surfaces is reduced
Solution Approach 1:
The leveling operation is performed preliminarily on each portion immediately after material deposition, while the material is still in a workable state and before solidification creates surface imperfections. This timing ensures effective leveling contact without requiring increased vertical distance, maintaining both precision and reliability.
Solution Approach 2:
The system dynamically adjusts the indexing position to bring fresh material portions under the leveling device as they are deposited. This dynamic coordination between material deposition and leveling actions ensures optimal contact conditions are maintained throughout the process, eliminating the need for increased vertical distance while preventing stalling.
Data Source
AI summary
A method of fabricating an object in layers, comprises, for at least one layer: dispensing a building material formulation to form a first portion of the layer, and leveling the first portion by a leveling device; increasing a vertical distance between the first portion and the leveling device; and while a topmost surface of the first portion is exposed and beneath a segment of the leveling device: dispensing a building material formulation to form a second portion of the layer, laterally displaced from the first portion along an indexing direction, and leveling the second portion by the leveling device.