Local Z Print Head Positioning for Non-Planar 3D Printing
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Solution Overview
Problem
Existing extrusion-based 3D printing systems are limited by print head movement in only two directions, which restricts toolpaths and joint types, and changing print heads in a heated chamber introduces thermal control challenges and prolongs the build process.
Innovation Solution
A 3D printer with a local Z positioner and x-y gantry system allows print heads to move in three dimensions, including a separate tool chamber for head exchange, maintaining thermal isolation and precise positioning through a linear motor-driven carriage and calibration chamber for accurate nozzle location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If print head movement is limited to two directions in a heated chamber, then thermal control is simplified, but toolpath flexibility and joint formation capability are restricted
Solution Approach 1:
The positioning system is segmented into two independent subsystems: an x-y gantry for horizontal movement and a local Z positioner for vertical movement. This segmentation allows each subsystem to be optimized independently, with the x-y gantry handling planar toolpaths and the local Z positioner enabling three-dimensional toolpaths and complex joint formations without increasing overall system complexity
Solution Approach 2:
The system transitions from two-dimensional x-y movement to three-dimensional positioning by adding the local Z positioner. This enables non-planar toolpaths and complex joint formations while maintaining thermal control through the separation of print head exchange operations from the heated chamber environment
2Productivity
If print head exchange is performed in the heated chamber, then thermal isolation is maintained, but thermal control stability deteriorates and build time increases
Solution Approach 1:
The print head exchange operation is extracted from the heated chamber environment and relocated to an overhead tool chamber. This allows print head changes to occur outside the heated zone, maintaining thermal control stability in the build chamber while enabling faster tool changes that improve overall productivity
Solution Approach 2:
Multiple print heads are pre-loaded in the overhead tool chamber, allowing for rapid exchange during the build process. This preliminary preparation of tools eliminates the need to remove the heated chamber or wait for thermal equilibration during print head changes, thereby maintaining thermal stability and reducing build time
3Ease of operation
If print head exchange requires chamber removal, then tool changing is simplified, but thermal control is disrupted and process time is prolonged
Solution Approach 1:
The overhead tool chamber serves multiple functions: it stores multiple print heads, provides a location for print head exchange, and maintains thermal isolation from the build chamber. This multi-functionality simplifies the tool changing operation while preventing thermal control disruption and reducing process time
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
Enables high-speed, accurate printing with non-planar toolpaths and efficient print head exchange, reducing thermal interference and time, while allowing complex joint formations and precise layer construction.
Implementation Method 1
The local Z positioner includes a linear motor which moves the print head in the z-direction
Data Source
AI summary
A 3D printer includes a gantry configured to move in a plane substantially parallel to a x-y build plane and a print head configured to extrude molten material to print a 3D part in a layer-by-layer process. The 3D printer includes a platen configured to support the part being printed in the layer by layer process and positionable with a primary Z positioner along a z-axis substantially normal to the x-y build plane. The 3D printer includes a local Z positioner moved by the gantry, the local Z positioner comprising a linear motor configured to move the print head in the z-direction and having an operable range of motion extending from a nominal build position at which a nozzle of the print head is positioned in the x-y build plane to a raised position above the x-y build plane.