Platen Planarizing Process for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing systems face challenges in achieving high-resolution printing due to non-planar platen surfaces, which can lead to layer height variations and reduced adhesive bonding, especially with large platens that are difficult and expensive to manufacture and install.
Innovation Solution
A method involving measuring the platen surface topography, generating a digital model of a planarizing part that compensates for surface deviations, and printing this part to create a substantially planar surface for subsequent 3D part and support structure printing, ensuring good adhesive bonding and high resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large platens are used to increase printing area, then productivity is improved, but manufacturing precision deteriorates due to difficulty in maintaining planarity
Solution Approach 1:
The patent applies preliminary action by printing a planarizing part before the actual 3D part to compensate for platen surface deviations. The system measures the platen topography, generates a compensating planarizing part model, prints it on the platen, and then uses this planarized surface for subsequent high-precision printing. This preliminary planarization enables large platens with reasonable tolerances to achieve high printing precision.
2Manufacturing precision
If traditional platen planarizing methods are used, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies self-service by using the additive manufacturing system itself to planarize the platen surface, rather than requiring external specialized equipment. The system measures its own platen, generates a compensating planarizing part, and prints it using its own extrusion mechanism. This eliminates the need for separate planarizing devices and reduces overall system complexity.
3Manufacturing precision
If traditional platen planarizing methods are used, then manufacturing precision is improved, but loss of time and substance increases
Solution Approach 1:
The patent merges the planarizing operation with the normal printing process by using the same extrusion tip and material deposition mechanism. The planarizing part is printed using the same additive manufacturing process as the 3D parts, combining two functions (planarization and part fabrication) into a single integrated operation, thereby reducing total time and material waste.
Data Source
AI summary
A method for printing a three-dimensional part with an additive manufacturing system, the method comprising generating and printing a planarizing part having a substantially-planar top surface relative to a build plane, and a bottom surface that substantially mirrors a topography of a platen surface, and printing the three-dimensional part over the substantially-planar top surface of the printed planarizing part.