3D Printer Positioning Member for Component Integration
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Solution Overview
Problem
Current three-dimensional object printing methods face challenges in precisely positioning pre-fabricated components due to high costs and complexities in machining and inspection, requiring intermingled operations with freshly printed structures for component support.
Innovation Solution
A three-dimensional object printer with a support member, positioning members, printhead, actuator, and controller that allows for precise placement and integration of components during the printing process, enabling the formation of objects with accurately positioned components without the need for initial machining of mounting features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision machining and inspection are used to position components in subtractive manufacturing, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a positioning member as an intermediary element between the support member and the component. This positioning member provides precise positioning through its geometric features (such as tapered surfaces and locating features) rather than requiring complex machining of the final object. The positioning member acts as a temporary mediator that holds the component in the correct position during printing, then can be removed after the object is formed.
Solution Approach 2:
The component is positioned in advance using the positioning member before the three-dimensional printing process completes. The positioning member pre-establishes the correct spatial relationship between the component and the support member, allowing the printer to then build around this pre-positioned component without needing to perform complex post-positioning operations.
2Manufacturing precision
If intermingled operations are used to install components in freshly printed structures, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The positioning member serves as a mediator that simplifies the manufacturing process by providing a straightforward mechanism for component placement. Instead of requiring complex intermingled operations where printed structures must be paused to install components, the positioning member provides a simple, pre-designed interface that makes component installation as straightforward as placing the component into the positioning member's holding features.
Solution Approach 2:
The positioning features are prepared in advance as part of the positioning member design, rather than requiring complex real-time operations during printing. The positioning member is configured beforehand with specific geometric features (tapered surfaces, locating features) that automatically guide component placement, eliminating the need for complex intermingled operations.
3Manufacturing precision
If positioning members are used to hold components during printing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The positioning function is segmented into a separate, removable positioning member that is distinct from both the support member and the final object. This segmentation allows the positioning functionality to be isolated in a dedicated component that can be designed, manufactured, and reused independently. The positioning member can be removed after use, and the same positioning member can be reused for multiple printing operations.
Solution Approach 2:
The positioning member is designed to be a universal fixture that can accommodate multiple different components through its geometric features. The tapered surfaces and locating features can work with various component shapes and sizes, making the positioning member a multi-functional tool rather than a specialized fixture for a single component type.
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 and cost-effective manufacture of three-dimensionally printed objects with precisely positioned components, reducing the need for extensive machining and inspection, and allowing for the reuse of the positioning device to facilitate multiple object productions.
Implementation Method 1
operating a curing device with the controller to cure the object structure
Data Source
AI summary
A printer is configured with positioning members that hold components at predetermined positions to enable a controller operating at least one printhead in a three-dimensional object printer to form structure about the components. The positioning members can then be removed from the printed three-dimensional object to enable continued formation of the three-dimensional object.