Print Foundation Indexing for Large Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing systems face challenges in printing large or elongated 3D items, as existing systems are limited by the dimensions of the build chamber, and accurately positioning and supporting such items during the printing process is difficult due to their size and weight.

Innovation Solution

The system employs a drive mechanism with a gantry and rail system to index a print foundation along a printing axis, allowing for the printing of long or tall items by moving the print foundation and using a touch probe for precise registration, and utilizes starter pieces and support structures to stabilize the item during printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the build chamber dimensions are increased to print larger items, then the printable volume is improved, but the system complexity and cost increase

Engineering Contradiction:

Improveprintable volumeVSAvoidsystem complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The system divides the printing process into segments by printing multiple layers onto a stationary print foundation, then indexing the foundation to a new position for continued printing. This segmentation allows the build chamber to remain compact while achieving arbitrary printing volumes through repeated indexing cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The print foundation is made dynamically repositionable through the indexing mechanism, allowing it to move between printing positions. This dynamic capability enables the same foundation to be used for printing items exceeding the chamber dimensions by repositioning the foundation between printing operations.

Inventive Principle:

Principle #15Dynamics

2Area of stationary object

If the print foundation is made larger to support larger items, then the printable area is improved, but the positioning accuracy and stability deteriorate

Engineering Contradiction:

Improveprint foundation areaVSAvoidpositioning accuracy

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The indexing mechanism acts as an intermediary between the print foundation and the build chamber, providing precise positioning of the foundation. This intermediary system enables accurate registration of the foundation at each indexing position, maintaining manufacturing precision despite the foundation's large size and the extended printing volume.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10562289B2Print foundation positioning and printing methods for additive manufacturing system

Publication Date: 2020.02.18 STRATASYS INC

AI summary

Method for printing a three-dimensional part layerwise with an additive manufacturing system includes printing layers by depositing material from a print head onto a print foundation, incrementing a position of the print head relative to the print foundation after each layer is printed, and indexing the print foundation carrying the printed layers away from the print head along the printing axis after a number of layers are printed. Printing is performed with driven and fixed rails clamped against movement of the print foundation. Moving the print foundation includes moving the driven rails with respect to the fixed rails in a direction substantially perpendicular to the build plane. Additive manufacturing system includes a drive mechanism to index the print foundation on the printing axis using fixed and driven rails, the driven rails engaging the print foundation for moving the print foundation.