3D Printer Head Automatic Touchdown Sensor Alignment
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Solution Overview
Problem
Current 3D printer heads face challenges in aligning relative to the support table and monitoring feedstock material quality, leading to inconsistencies in the printing process.
Innovation Solution
A three-dimensional printer head with a drive motor, feed plate, z-axis plate assembly, and sensor system that automatically locates and measures the position and force of the print nozzle relative to the support table, ensuring precise alignment and monitoring of filament deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for the printer head relative to the support table, then device complexity is reduced, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated sensor-based system. Sensors detect the position of the support table relative to the printer head and provide feedback to automatically adjust alignment, substituting human-operated mechanical procedures with an automated electromechanical system that achieves higher precision without requiring manual intervention.
Solution Approach 2:
The alignment system performs self-alignment through automated sensor feedback and control mechanisms. The system monitors its own position and automatically adjusts the printer head or support table alignment without external intervention, enabling the device to service itself and maintain precise alignment consistently.
2Manufacturing precision
If automated sensor systems are added for touchdown detection, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent replaces mechanical touchdown detection methods with sensor-based detection systems. These sensors automatically detect when the support table contacts the build platform, providing precise electronic signals for position feedback without the complexity of mechanical switches or contact-based detection mechanisms.
Solution Approach 2:
The sensor system implements feedback by continuously monitoring the position of the support table and relayin gthis information to the control system. This feedback loop enables real-time adjustments and precise touchdown detection, allowing the system to maintain accuracy while automating the alignment process.
3Manufacturing precision
If real-time monitoring of filament deposition is implemented, then manufacturing precision improves, but use of energy increases
Solution Approach 1:
The patent replaces physical inspection methods with sensor-based monitoring for detecting filament deposition irregularities. Optical sensors or other detection devices monitor the deposition process in real-time, substituting manual visual inspection or mechanical measurement methods that would require more energy-intensive equipment or human intervention.
Solution Approach 2:
The monitoring system operates continuously during the printing process, providing ongoing detection of filament deposition quality without interrupting the printing workflow. This continuous monitoring approach allows for real-time quality control while maintaining efficient energy usage by keeping the system in a low-power standby mode between measurement cycles.
Data Source
AI summary
A three-dimensional printer head includes a drive motor, the drive motor including a drive shaft, a feed plate is affixed to the drive motor, and a feed hob is mounted to the drive shaft. The feed hob includes drive teeth configured to engage a filament. An idle assembly mounted to the feed plate configured to bias the filament against the drive teeth. The printer head further includes a z-axis plate assembly, wherein the z-axis plate assembly includes at least two flexures coupling a z-axis plate to the feed plate and a print nozzle mounted to the z-axis plate assembly. The printer head also includes a sensor coupled to the feed plate, wherein the sensor is configured to be triggered by the z-axis plate assembly when the z-axis plate assembly moves a given distance in a first direction.