Multi-Dimensional Build Platform for Support-Free 3D Printing
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Solution Overview
Problem
Existing additive manufacturing systems face inefficiencies and increased costs due to the use of planar build plates, especially when fabricating complex geometries with multiple material characteristics and tools, leading to increased build time and material usage, particularly when dealing with overhangs and hollow areas.
Innovation Solution
A multi-dimensional build platform with individually addressable elements and functional characteristics, allowing for dynamic reconfiguration and support-free fabrication across multiple axes, including features like temperature, magnetic fields, and light, to enhance fabrication capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If planar build plate geometries are used in additive manufacturing systems, then the system is suitable for common additive manufacturing processes, but the system becomes less efficient and limited when fabricating complex geometries with multiple material characteristics and tool axes
Solution Approach 1:
The patent transitions from planar (2D) build plates to non-planar (3D) build platforms with curved surfaces, varying thickness, and complex geometries. This dimensional change enables direct fabrication of complex objects without extensive support structures, as the build platform itself provides the necessary geometric complexity and support functions.
Solution Approach 2:
The build platform is designed with dynamically reconfigurable properties including variable thickness, curved surfaces, and adjustable material characteristics. These dynamic features allow the platform to adapt to different fabrication requirements, enabling complex geometries to be built directly without fixed support structures.
2Manufacturing precision
If extensive support structures are used to fabricate complex geometries, then the target object can be formed, but the production time increases and material cost increases
Solution Approach 1:
The patent extracts the support function from separate support structures and integrates it into the build platform itself. The non-planar build platform provides inherent support for overhangs and complex geometries through its three-dimensional form, eliminating the need for additional support materials that would require post-processing removal.
Solution Approach 2:
The build platform merges multiple functions into a single component: it provides the building surface, structural support, geometric complexity, and material deposition substrate. This consolidation eliminates the need for separate support structures and reduces the number of fabrication steps required.
3Adaptability or versatility
If multiple tools and material characteristics are used to fabricate complex objects, then the functionality of the target object is enhanced, but the number of geometric tool axes and tool-path complexity increases
Solution Approach 1:
The non-planar build platform serves multiple functions simultaneously: it provides deposition surfaces for multiple tools, supports various material characteristics, and enables complex geometries without requiring additional geometric axes. The platform's three-dimensional form factor allows different tools to operate from various angles and positions.
Solution Approach 2:
By moving from 2D planar to 3D non-planar build platforms, the system gains an additional dimensional degree of freedom that reduces the need for multiple geometric tool axes. The vertical and radial dimensions of the non-planar platform provide access and support that would otherwise require additional rotational or lateral axes.
4Device complexity
If planar build plates are used with multi-axis additive manufacturing systems, then the system maintains simplicity, but the build time increases and additional processes are required
Solution Approach 1:
The non-planar build platform is pre-configured with the geometric complexity and support structures needed for the target object. This preliminary formation of the build platform eliminates the need for post-fabrication support removal and reduces the number of processing steps required during and after additive manufacturing.
Data Source
AI summary
An additive manufacturing system, a build platform and a method of operating are provided. The build platform includes an interface section configured to couple with the additive manufacturing system. A base section is coupled to the interface section. A build volume is provided having at least one layer having at least one individually addressable element that includes at least one of a feature characteristic or functional characteristic.