Modular Additive Manufacturing System for Biomedical Printing

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Solution Overview

Problem

Conventional 3D printers, particularly 3D bioprinters, face challenges in accurately locating the printing head and precisely tracking material deposition, leading to difficulties in manufacturing complex biomedical products efficiently and accurately under varying environmental conditions.

Innovation Solution

A modular system comprising at least two additive manufacturing devices with a hermetically-sealed housing, a printer head and axis system, and a movement mechanism, controlled by a software module to move the manufacturing tray between devices, allowing for precise printing under different conditions and material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple conventional 3D printers are used for successive processes with varying environmental conditions and materials, then manufacturing versatility is improved, but device complexity and transfer difficulty increase

Engineering Contradiction:

Improvemanufacturing versatilityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system divides the additive manufacturing process into multiple independent modules, each capable of performing specific printing operations with different materials and environmental conditions. Each module contains its own printing head, extruder, and controlled chamber, allowing them to operate independently while contributing to a unified manufacturing workflow.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modules are designed with universal interfaces and standardized mounting mechanisms that allow them to perform multiple functions. Each module can handle different printing technologies (FDM, SLA, SLS) and materials, and can be configured for various environmental conditions, making the entire system highly adaptable without requiring separate dedicated machines.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple conventional 3D printers are used for successive processes, then manufacturing versatility is improved, but transfer time and operational difficulty increase

Engineering Contradiction:

Improvemanufacturing versatilityVSAvoidtransfer time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Multiple printing modules are merged into a single integrated system with a shared build platform and coordinated control architecture. The modules are arranged in a modular cluster where the build platform can be positioned within any module, eliminating the need to physically transfer objects between separate machines and reducing transfer time to minimal repositioning movements.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If conventional 3D bioprinters are used, then basic printing capability is provided, but location accuracy and material deposition precision are insufficient

Engineering Contradiction:

Improveprinting capabilityVSAvoidhead location accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system incorporates real-time feedback mechanisms including encoders on all motion axes, force sensors on the printing head, and vision systems for monitoring material deposition. The control module continuously receives data from these sensors and adjusts printing parameters dynamically to maintain sub-micron positioning accuracy and precise material deposition rates, far exceeding conventional bioprinter capabilities.

Inventive Principle:

Principle #23Feedback

4Ease of operation

If conventional 3D bioprinters are used, then basic printing capability is provided, but material deposition tracking precision is insufficient

Engineering Contradiction:

Improveprinting capabilityVSAvoidmaterial deposition tracking

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system replaces conventional mechanical measurement methods with advanced sensing technologies including capacitive sensors, optical interferometry, and mass flow meters integrated into the material delivery system. These sensors provide real-time, high-precision measurement of material deposition volume, rate, and distribution, with accuracy tracked and recorded by the control module for quality assurance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3877155B1Modular systems and methods for performing additive manufacturing of objects

Publication Date: 2023.09.06 BRINTER OY

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AI summary

Disclosed is a modular system (100) for performing additive manufacturing of an object. The system comprises at least two additive manufacturing devices (102,104), wherein each of the at least two additive manufacturing devices comprises a housing having two slots (206) on lateral sides to accommodate a manufacturing tray (208); a printer head (210, 212) and axis system; and a movement mechanism. Furthermore, the system comprises a control module (106) operatively coupled to each of the at least two additive manufacturing devices. The control module is configured to control the at least two additive manufacturing devices to arrange the manufacturing tray in a first of the at least two additive manufacturing devices; print a part of the object on the manufacturing tray arranged in the first additive manufacturing device; move the manufacturing tray having the partially manufactured object to a second of the at least two additive manufacturing devices; and print a remaining part of the object on the manufacturing tray to complete the additive manufacturing of the object.