Moveable Carriage IR Emitter for Additive Manufacturing Heating
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Solution Overview
Problem
Large 3D printing systems face increased costs and power consumption due to the need for numerous static shortwave IR emitters to achieve spatial resolution for larger build zones, leading to inefficiencies in heating and potential defects in printed objects.
Innovation Solution
A moveable carriage with a thermal sensor and radiation device that can switch between preheating and fusing modes, allowing for localized and efficient heating by applying radiation during both stages, reducing the need for multiple emitters and improving energy distribution based on measured temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If numerous static shortwave IR emitters are used to achieve spatial resolution for larger build zones, then the heating coverage is improved, but the power consumption and system cost increase
Solution Approach 1:
The patent converts the static emitter array into a dynamic system by mounting the shortwave IR emitter on a moveable carriage that travels along the build zone. This allows a single emitter to sequentially cover different areas, replacing the need for numerous static emitters and significantly reducing power consumption while maintaining full build zone coverage.
Solution Approach 2:
The moveable carriage system performs multiple functions: it positions the emitter to cover different regions of the build zone, adjusts the emitter height for optimal heating, and enables both preheating and fusing operations with the same hardware, making the system more versatile and efficient.
2Area of stationary object
If numerous static shortwave IR emitters are used to achieve spatial resolution, then the heating coverage is improved, but the device complexity increases
Solution Approach 1:
The system replaces a complex static array of multiple emitters with a simpler dynamic system consisting of a single emitter mounted on a moveable carriage. The carriage's movement along predetermined paths enables comprehensive coverage without requiring complex coordination of multiple independent emitter units.
Solution Approach 2:
The patent combines the emitter, carriage, and control mechanisms into an integrated moveable assembly. This merging of components simplifies the overall system architecture compared to managing multiple separate static emitter units, reducing device complexity while maintaining heating coverage.
3Device complexity
If static emitters are used for heating, then the system structure is simple, but heating efficiency is reduced due to inability to apply radiation based on measured temperature
Solution Approach 1:
The system incorporates thermal imaging cameras that continuously monitor the temperature distribution across the build zone. This thermal data feeds back to the controller, which adjusts the emitter's position, height, and operation mode (preheating or fusing) to optimize heating efficiency and eliminate energy waste from uniform heating of already-sufficient areas.
Solution Approach 2:
The system dynamically changes operational parameters including emitter position, height above build material, and radiation intensity based on real-time thermal feedback. This allows the system to adapt heating parameters to actual temperature conditions, significantly improving heating efficiency compared to fixed static emitter configurations.
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
This approach enhances heating efficiency, reduces power consumption, and minimizes defects such as uneven surfaces and excess material attachment, resulting in objects with better structural integrity and aesthetic quality.
Implementation Method 1
a thermal sensor device (160) on the carriage is to obtain thermal data associated with a region of build material
Implementation Method 2
the radiation device (170) on the carriage is to apply radiation onto the build material, and is configurable between a preheating mode and a fusing mode
Implementation Method 3
In the fusing mode, the radiation device (170) is to apply radiation onto the build material to selectively fuse the build material
Data Source
AI summary
Certain examples described herein relate to a carriage assembly for an additive manufacturing system. The carriage assembly comprises a movable carriage to move over a build zone of the additive manufacturing system, a thermal sensor device on the carriage to obtain thermal data associated with a region of build material in the build zone, radiation device on the carriage to apply radiation onto the build material. The radiation device is configurable between a preheating mode, to apply radiation onto the region of build material to raise a surface temperature thereof, and a fusing mode, to apply radiation onto the region of build material to selectively fuse at least part of the region of build material.