Modular Metal 3D Printer Build Plate for Large-Scale Flatness
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Solution Overview
Problem
Traditional CNC machining becomes infeasible for achieving the required surface finish and flatness as the size of metal 3D printers increases, limiting the scalability of metal 3D printer systems.
Innovation Solution
A metal 3D printing build plate system that uses the machining capabilities of a 3D metal printing robot to achieve the required surface finish and flatness on a reusable build plate, allowing for printing of metal structures up to 18 feet in diameter or larger without relying on traditional CNC machines, by constructing a large-welded assembly with multiple CNC machined sections and leveraging in-cell machining capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional CNC machining is used to achieve required surface finish and flatness on large build plates, then manufacturing precision is maintained, but device complexity and infeasibility increase as printer size increases
Solution Approach 1:
The build plate is divided into multiple smaller CNC-machined sections that are assembled together to form a large annular surface. This segmentation allows standard CNC machines to manufacture each section with required precision, while the overall build plate can scale to large diameters without requiring oversized CNC equipment.
Solution Approach 2:
The metal 3D printer robot performs in-cell machining operations on the build plate surface itself, using its own machining capabilities to achieve required flatness and surface finish. This eliminates the need for external CNC machining operations and allows the system to be self-sufficient for build plate preparation.
2Manufacturing precision
If traditional CNC machining is used for build plate construction, then surface finish and flatness are achieved, but productivity decreases due to reliance on external machining operations
Solution Approach 1:
The 3D printing robot is equipped with both additive manufacturing capabilities and in-cell CNC machining capabilities in a single integrated system. This merging allows the same robot to both prepare the build plate surface through machining and subsequently print parts, eliminating the need for separate external machining operations and accelerating production cycles.
3Ease of manufacture
If large-welded assembly with loose control is used for build plate base, then ease of manufacture increases, but manufacturing precision of the printing surface deteriorates
Solution Approach 1:
The build plate consists of a large welded assembly base with loosely controlled flatness, upon which multiple precisely CNC-machined sections are mounted to form the final printing surface. This segmentation allows the base to be easily manufactured through welding while the critical printing surface achieves high precision through separate machining of individual sections.
Solution Approach 2:
Different regions of the build plate structure serve different functions: the base welded assembly provides structural support with loose tolerance control, while the mounted machined sections provide the precision printing surface. This local quality differentiation allows each region to be optimized for its specific function without compromising the other.
Data Source
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AI summary
A machinable 3-D printing build plate that can be assembled from a number of different components into the base for a metallic 3-D printing volume and other 3-D printed parts. The build plate can be assembled into a final structure then machined to the required planar tolerance such that the build quality of the part is maintained throughout the build. Additionally, because the baseline printer support structure and support device are comprised of multiple elements, if one or more goes out of tolerance or requires adjustment to accommodate a new print, it may be easily removed, replaced then machined back to the required tolerances.