3D Printer Sensor Detects Obstructions
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Solution Overview
Problem
Three-dimensional (3D) printers face damage and operational issues when operators forget to unload completed articles, leading to damage of existing articles and equipment.
Innovation Solution
A three-dimensional printing system incorporating a movement mechanism, support tray, resin vessel with a transparent sheet, light engine, sensor, and controller that detects polymerized build material and halts the process if a completed article is present, providing user notifications and optionally fabricating a flag feature to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no detection system is installed, then the printer operates continuously without interruption, but damage occurs to the printer and existing articles when operators forget to unload completed articles
Solution Approach 1:
A sensor acts as an intermediary detection device that monitors the support tray for the presence of completed articles. The sensor detects optical properties or physical presence of polymerized material and sends signals to the controller, enabling indirect detection without requiring complex direct monitoring of the entire printing process
Solution Approach 2:
The system implements feedback control by continuously monitoring the support tray state through the sensor and providing real-time information to the controller. When a completed article is detected, the controller receives feedback and automatically halts the printing process, creating a closed-loop system that prevents damage through continuous state verification
2Reliability
If the build process is halted frequently to check for completed articles, then damage to the printer is prevented, but productivity decreases due to interruptions
Solution Approach 1:
The sensor performs preliminary detection of completed articles during the printing process itself, rather than requiring separate inspection steps. The continuous monitoring capability allows the system to detect completion status in advance, enabling automatic halting at the precise moment of completion without requiring frequent manual checks or process interruptions
Solution Approach 2:
The system performs self-monitoring and self-protection by automatically detecting when an article is complete and halting the process without human intervention. The controller autonomously manages the printing process based on sensor feedback, eliminating the need for operator intervention and maintaining continuous operation until completion is detected
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
Prevents damage to the printer and ensures proper unloading of completed articles by detecting and halting the build process when a full support tray is detected, allowing for safe replacement and continued operation.
Implementation Method 1
a sensor and a controller. The controller is configured to (a) receive a start indication for a build process, (b) operate the sensor, (c) determine if polymerized build material is in the flag region from the sensor signal
Implementation Method 2
The light engine projects pixelated light through the transparent sheet and to a build plane
Data Source
AI summary
A three dimensional printing system for manufacturing a three dimensional article includes a movement mechanism, a support tray, a resin vessel, a light engine, a sensor, and a controller. The support tray is mounted to the movement mechanism and has a lower surface for supporting the three dimensional article. The resin vessel includes a transparent sheet defining a lower bound for resin contained therein. The light engine projects pixelated light through the transparent sheet and to a build plane. The controller is configured to (a) receive a start indication for a build process, (b) operate the sensor, (c) determine if polymerized build material is in a flag region from the sensor signal, and (d) if polymerized build material is determined to be in the flag region, halt the build process.