3D Printer Leveling System with Corner Actuators
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Solution Overview
Problem
Maintaining parallelism and precise control of the gap between working planes in 3D printing systems for laser dispensing is challenging, especially for high viscosity inks, which often clog nozzles and require accurate alignment to ensure proper laser focusing and printing quality.
Innovation Solution
A leveling system utilizing vertically oriented linear actuators at the corners of two frames, allowing independent control of each frame's position and angle to maintain parallelism and precise gap control between the optical and receiving planes, with additional sensors for monitoring and processor-based control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thin layer of ink is transported on an intermediary layer or mesh screen, then laser-based droplet jetting can be achieved, but maintaining parallelism and precise gap control between working planes becomes difficult for large size object printing
Solution Approach 1:
The system divides the large print area into multiple zones with independent actuators positioned at corners and intermediate locations. Each actuator controls a specific region's height and angle independently, allowing parallelism maintenance across the entire large area through coordinated segmentation of control zones.
Solution Approach 2:
The system employs dynamic actuators that can independently adjust the height and angular orientation of frame sections in real-time. This dynamic adjustment capability allows the system to maintain precise parallelism and gap control across large print areas by continuously adapting to positional variations.
2Manufacturing precision
If vertical linear actuators are used at corners of frames, then parallelism and gap control can be achieved, but device complexity increases
Solution Approach 1:
The actuators are designed to perform multiple functions simultaneously: they control both the vertical height and the angular orientation of frame corners. This multi-functionality reduces the need for separate adjustment mechanisms, thereby managing device complexity while achieving precise parallelism control.
Solution Approach 2:
The system replaces complex mechanical linkage systems with vertically oriented linear actuators that directly control corner positions. This substitution simplifies the mechanical structure by using independent linear actuators instead of interconnected mechanical adjustment mechanisms.
3Reliability
If high viscosity ink is used to avoid nozzle clogging, then printing reliability improves, but maintaining precise gap control becomes more challenging
Solution Approach 1:
The system incorporates sensors that provide feedback on the actual gap distance and parallelism between working planes. This feedback enables real-time adjustments by the actuators to maintain precise gap control, which is critical when using high viscosity ink that requires consistent laser focusing for reliable printing.
Data Source
AI summary
A leveling system for a 3D printing system for laser dispensing includes inner and outer frames, each supported at its corners by respective actuators of first and second sets of actuators. The outer frame supports an optical plane within which material to be dispensed by laser irradiation is disposed. The inner frame supports a receiving medium plane within which a substrate on which said material to be dispensed by laser irradiation is disposed. Each actuator operates independently to displace a respective frame corner in the vertical direction. The inner and outer frames each is attached at their respective corners to a respective actuator by a rod, thus allowing the inner and outer frames to freely rotate with respect to one another. An additional frame may support sensors for monitoring the 3D printing system.