Multi-Tray 3D Printing System Parallel Processing
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Solution Overview
Problem
Existing 3D powder layer printing systems are inefficient as most stations are idle at any given time, limiting the concurrent manufacturing of multiple objects with varying layer thicknesses and heights.
Innovation Solution
A 3D printing system that utilizes multiple building trays, each advancing through a series of stations (mask printing, powder dispensing, spreading, and compaction) concurrently, allowing for simultaneous construction of multiple objects with different materials and layer thicknesses, and enabling objects at different stages of completion to be built on the same trays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single building tray is used with sequential process stations, then the system structure is simple, but the productivity is low because most stations are idle at any given time
Solution Approach 1:
The system divides the single building tray into multiple building trays (first building tray, second building tray, etc.), each capable of holding and processing different objects independently. This segmentation allows multiple process stations to work simultaneously on different trays, eliminating idle time and significantly improving productivity without requiring complex coordination mechanisms.
Solution Approach 2:
The invention transitions from a single-tray sequential processing system to a multi-tray parallel processing system by adding the dimension of multiple trays. Each tray cycles independently through the process stations (mask printing, powder dispensing, spreading, compaction), enabling concurrent manufacturing of multiple objects with varying complexities and heights.
2Productivity
If multiple objects with different layer thicknesses and heights are manufactured concurrently, then the productivity improves, but the manufacturing precision becomes difficult to maintain
Solution Approach 1:
The system applies local quality by allowing each building tray to have customized process parameters tailored to the specific object being manufactured. Each tray can receive mask patterns, powder doses, spreading forces, and compaction pressures optimized for its particular object's requirements (different layer thicknesses, heights, materials), ensuring manufacturing precision is maintained even when producing diverse objects concurrently.
Solution Approach 2:
The system implements dynamic parameter adjustment where process station settings can be modified in real-time based on the specific object and tray being processed. This dynamic adaptability allows the system to maintain precise control over layer thickness and quality metrics while concurrently manufacturing objects with varying specifications.
3Loss of time
If a single process station operates sequentially on one tray, then the device complexity is low, but the loss of time increases due to idle stations
Solution Approach 1:
The system achieves continuity of useful action by having multiple building trays cycle through the process stations in an overlapping manner. While one tray is being masked, another is receiving powder, a third is being spread, and a fourth is being compacted. This continuous workflow eliminates idle time at process stations, as each station always has a tray to work on, maximizing the utilization of all equipment.
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 significantly reduces manufacturing time by keeping multiple stations occupied and allows for the efficient construction of multiple objects with varying complexities and heights, improving the overall efficiency of the 3D printing process.
Implementation Method 1
Some known 3D printing techniques selectively apply a liquid binder material based on a 3D model of the object that binds the material together layer by layer to create a solid structure
Implementation Method 2
performing die compaction on the layer
Implementation Method 3
sintering the layer that is die compacted by selective sintering or selective melting
Implementation Method 4
Selective laser melting (SLM) is comparable technique that applies full melting of the material instead of sintering
Data Source
AI summary
A system includes a plurality of building trays, a printing station, a powder delivery station, a powder spreading station, a process compaction station and a stage. The printing station prints a mask pattern on each of the plurality of building trays. The powder delivery station applies a dose of powder material on each of the plurality of building trays. The powder spreading station configured to spread the dose of powder material on each of the plurality of building trays. The process compaction station compacts the powder material. The stage concurrently advances the plurality of building trays to each of the stations to concurrently build a single layer on each the plurality of building trays and repeats the advancing to build a plurality of layers on each of the plurality of building trays. A three dimensional object is formed in each of the building trays.