Multi-Nozzle Extrusion Controller for Additive Manufacturing
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Solution Overview
Problem
Extrusion-based additive manufacturing systems are inefficient and slow for mass production of porous structures, requiring improvements in speed and productivity without increasing costs or ecological footprint.
Innovation Solution
A method and system that utilize a controller and multiple nozzle heads to monitor and manage operational failures during the printing process, allowing for real-time detection and correction of errors, and decision-making based on statistical models to optimize print job continuation or interruption for increased productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple nozzle heads are used for parallel printing to increase productivity, then production speed increases, but the probability of operational failures increases
Solution Approach 1:
The system divides the printing task into multiple independent nozzle heads, each capable of printing separate structures in parallel. This segmentation increases productivity while the monitoring system tracks each nozzle's performance individually to manage reliability risks.
Solution Approach 2:
The system implements real-time monitoring of each nozzle head's operation, detecting failure events and calculating their impact on overall productivity. This feedback mechanism enables dynamic decision-making about whether to continue or interrupt printing based on actual nozzle performance data.
2Manufacturing precision
If the print job is interrupted for nozzle repair, then printing quality improves, but production time increases
Solution Approach 1:
The system performs preliminary calculation of the impact of nozzle failures on overall productivity before making the decision to interrupt or continue printing. By evaluating the expected loss from continued printing with failing nozzles versus the interruption time, the system optimizes the decision to minimize total production time while maintaining quality.
Solution Approach 2:
The system changes the operational parameters dynamically by deciding whether to continue or interrupt based on calculated productivity impact. This parameter change (continuation vs. interruption decision) optimizes the balance between maintaining printing quality and minimizing production time loss.
3Loss of time
If the print job is continued with failing nozzles, then production time is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The system performs preliminary calculation of the impact of nozzle failures on overall productivity before making the decision to interrupt or continue printing. By evaluating the expected loss from continued printing with failing nozzles versus the interruption time, the system optimizes the decision to minimize total production time while maintaining quality.
Solution Approach 2:
The system changes the operational parameters dynamically by deciding whether to continue or interrupt based on calculated productivity impact. This parameter change (continuation vs. interruption decision) optimizes the balance between maintaining printing quality and minimizing production time loss.
Data Source
AI summary
A method and system for controlling an extrusion system (1) having a plurality of nozzle heads (7) for depositing a predetermined interconnected arrangement for concurrently forming individual three-dimensional structures (3) in parallel. An operation of each of the plurality of nozzle heads is monitored in order to detect failing nozzle heads, wherein a first value is calculated which is indicative of an average print time for finishing a number of three-dimensional structures when the print job is continued using one or more non-failing nozzle heads of the plurality of nozzle heads which are still operational, and a second value is calculated indicative of an average print time for finishing the number of three-dimensional structures when the print job is promptly interrupted and a new print job is initiated with the one or more failing nozzle heads of the plurality of nozzles heads being repaired. The controller is configured to restart the print job with the one or more failing nozzle heads being repaired, when the second value is smaller than the first value.