Multi-Tool 3D Printing with Time-Shifted Seam Placement
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Solution Overview
Problem
Traditional additive manufacturing methods, such as Fused Filament Fabrication (FFF), often result in visible seams and require sequential operation of tools, limiting efficiency and strength in building complex 3D parts.
Innovation Solution
A multi-tool additive manufacturing system with multiple robots that can operate independently and simultaneously in a shared three-dimensional build volume, using coordinated tool paths to minimize seams and enhance bonding between parts, allowing for interchangeable tools like additive, subtractive, and milling tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple additive manufacturing tools operate simultaneously in a shared build volume, then productivity is improved, but device complexity increases
Solution Approach 1:
The build volume is divided into multiple regions, with each additive manufacturing tool assigned to a specific region. This segmentation allows simultaneous operation of multiple tools without interference, directly improving productivity while managing system complexity through spatial organization
Solution Approach 2:
The system transitions from sequential single-tool operation to parallel multi-tool operation by utilizing the three-dimensional build volume as an additional operational dimension. Multiple tools work simultaneously in different spatial regions, effectively adding a temporal dimension to the manufacturing process
2Manufacturing precision
If tool paths are coordinated to minimize seams, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Tool paths are pre-planned and coordinated before manufacturing begins. The system determines optimal seam locations and adjusts tool paths in advance to minimize visible seams, ensuring manufacturing precision without requiring complex real-time coordination during operation
Solution Approach 2:
The system adjusts tool path parameters such as seam location, tool path direction, and layer orientation to minimize visible seams. By changing these parameters in the planning stage, the system achieves high manufacturing precision while keeping the actual manufacturing process relatively simple
3Productivity
If multiple robots operate in contiguous regions, then productivity is improved, but the risk of collision increases
Solution Approach 1:
The build volume is segmented into distinct regions for each robot, with clearly defined boundaries. This spatial segmentation allows robots to operate in contiguous regions simultaneously while maintaining safe distances, improving productivity without increasing collision risk
Solution Approach 2:
The system implements real-time monitoring and coordination of robot positions and movements. By continuously tracking robot locations and adjusting tool paths as needed, the system enables fast simultaneous operation while maintaining high reliability through active collision prevention
Data Source
AI summary
Methods, systems, and computer programs for multi-tool additive manufacturing include a method including: slicing a received model into a series of layers; determining one or more separation starting points, each being a location of two adjoining portions of the model that are to be manufactured by respective additive manufacturing robots; and determining an offset for each of the one or more separation starting points in each layer of the series of layers based on a threshold acceptable print time, each offset in a layer determining a seam location in the layer that is different from a seam location in at least one adjacent layer in the series of layers, and seam offsets determined for the series of layers increase an estimated print time, for manufacturing of the series of layers by the two or more additive manufacturing robots, to no more than the threshold acceptable print time.