Single-Gantry Near-Net-Shape Printing With Movable Work Table
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing machines with separate printing and trimming gantries are costly and unsuitable for smaller machines, increasing size and complexity, and the process of melting thin filaments for 3D printing is slow for large items.
Innovation Solution
A single-gantry machine design that integrates both printing and trimming operations, allowing for near net shape additive manufacturing with reduced costs and space requirements, using a fixed gantry and movable work table with separate print and trim heads, and optional vertical printing configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate printing and trimming gantries are used, then printing and trimming operations can be performed independently, but the machine size and complexity increase significantly
Solution Approach 1:
The patent combines both printing and trimming operations onto a single gantry system. The gantry supports both a print head for additive manufacturing and a trim head for post-processing operations, allowing both functions to be performed on one integrated machine rather than requiring separate gantries. This merging reduces machine size and structural complexity while maintaining both operational capabilities.
Solution Approach 2:
The single gantry is designed to perform multiple functions by supporting different tool heads. It can switch between the print head for depositing material layers and the trim head for trimming and finishing operations. This multi-functional design allows one gantry structure to replace what would traditionally require two separate gantries, reducing overall machine complexity.
2Manufacturing precision
If thin filament melting process is used for 3D printing, then detailed and precise components can be produced, but the production speed is too slow for large items
Solution Approach 1:
The patent employs dynamic adjustment of printing parameters based on the build stage. During initial rapid bulk deposition phases, less precise but faster parameters are used to build up material quickly. As the build progresses and finer details are required, the system dynamically adjusts to more precise deposition parameters. This dynamic adaptation allows the system to optimize between speed and precision at different stages of the same build process.
3Productivity
If large print bead is used for near net shape manufacturing, then production speed increases, but additional machining time is required to achieve final dimensions
Solution Approach 1:
The patent performs trimming and finishing operations immediately after each printing layer or sequence of layers, rather than waiting until the entire print is complete. This preliminary action on the workpiece allows the build to progress continuously while minimal post-processing is performed incrementally. The trim head makes quick adjustments to achieve near-final dimensions as the print builds, reducing the need for extensive final machining and optimizing total fabrication time.
4Device complexity
If a single gantry with both print and trim heads is used, then machine size and cost are reduced, but the gantry must be large enough to accommodate both operations
Solution Approach 1:
The patent arranges the print head and trim head in different spatial dimensions along the gantry structure. Rather than requiring excessive horizontal separation, the heads are positioned at different locations along the gantry's length, utilizing the available dimensional space efficiently. This spatial arrangement allows both heads to operate independently without requiring an excessively large gantry span, optimizing the balance between accommodating both operations and minimizing machine footprint.
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
Enables efficient fabrication of large components with reduced space and cost, by combining printing and trimming on a single machine, and allows for faster production through larger bead deposition and vertical printing capabilities.
Implementation Method 1
Friction from the rotating screw, combined with heat from the barrel, may soften the plastic
Implementation Method 2
heat from the barrel, may soften the plastic
Implementation Method 3
Friction from the rotating screw, combined with heat from the barrel, may soften the plastic
Implementation Method 4
The flowable material, such as, e.g., molten thermoplastic material, may be deposited upon a substrate
Implementation Method 5
deposited upon a substrate (e.g., a mold), and then pressed down or otherwise flattened and/or leveled to a consistent thickness
Implementation Method 6
Traditional print heads may include an oscillating plate surrounding the nozzle, the plate being configured to oscillate vertically to flatten the bead of material
Data Source
AI summary
An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.