Modular Metal 3D Build Plate With In-Cell CNC Flattening
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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 in-cell CNC machining capabilities of a 3D metal printing robot to achieve the necessary surface finish and flatness, allowing for larger-scale metal 3D printing without relying on external machining operations, with a reusable build plate composed of multiple CNC machined sections that can be machined to precise tolerances using a laser scanner or dial indicator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional CNC machining is used to achieve required surface finish and flatness, then manufacturing precision is improved, but device complexity and scalability worsen as printer size increases
Solution Approach 1:
The patent merges the machining function with the 3D printing robot by equipping the robot with in-cell CNC machining capabilities. This integration allows the same robot to perform both additive manufacturing and precision machining operations, eliminating the need for separate external machining operations and enabling scalability to large printer sizes up to 18 feet in diameter.
Solution Approach 2:
The 3D printing robot is designed with multi-functionality, serving both as an additive manufacturing device and a CNC machining center. The robot's end effector can switch between printing tools and machining tools, allowing a single device to achieve both construction and precision finishing tasks on build plates of varying sizes.
2Manufacturing precision
If external machining operations are used for build plate construction, then manufacturing precision is improved, but productivity decreases due to additional operational steps
Solution Approach 1:
The machining operation is merged with the printing process by performing both operations within the same print cell using the same robot. This eliminates the need to transport build plates between separate machining centers and printing equipment, significantly reducing setup time and operational steps while maintaining precision.
Solution Approach 2:
The build plate is pre-assembled as a large welded assembly with loose control over flatness, then machined to precise tolerances using the robot's in-cell machining capabilities before or during the printing process. This preliminary machining action within the print cell eliminates the need for post-assembly adjustments and external machining operations.
3Productivity
If in-cell CNC machining is used, then productivity is improved by eliminating external operations, but device complexity increases due to integrated machining capabilities
Solution Approach 1:
The robot system achieves multi-functionality by equipping the same robot with both printing and machining capabilities through interchangeable end effectors. This approach increases productivity by eliminating external operations while managing device complexity through a modular tooling system rather than separate dedicated machines.
Data Source
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.