3D Printer Support Tray Positioning via Linear Bearing
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Solution Overview
Problem
Existing three-dimensional printing systems, particularly stereolithography, face challenges in providing precision vertical movements during the fabrication of solid articles from photocurable resins, which affects the accuracy and speed of the manufacturing process.
Innovation Solution
A three-dimensional printing system incorporating a support tray positioning system with a motorized lead screw, intermediate nut, and linear bearing, which constrains rotational motion while allowing for precise linear vertical movement, accommodates mechanical tolerances, and enables two-dimensional lateral motion to ensure accurate positioning of the support tray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a motorized lead screw is used for vertical movement, then the speed and precision of layer formation is improved, but rotational motion of the support tray occurs causing positioning errors
Solution Approach 1:
A linear bearing is introduced as an intermediary component between the support tray and the lead screw mechanism. The linear bearing allows pure linear vertical motion while constraining any rotational movement, thereby eliminating the positioning errors caused by rotation while preserving the precision benefits of the lead screw mechanism.
2Manufacturing precision
If the support tray is constrained to linear motion only, then rotational positioning errors are eliminated, but mechanical tolerances cannot be accommodated
Solution Approach 1:
The support tray positioning system transitions from a rigid fixed constraint to a dynamic adaptive constraint. The linear bearing provides a constrained motion path that can dynamically adjust within its clearance tolerances to accommodate manufacturing variations, while still preventing rotational movement that would cause positioning errors.
Solution Approach 2:
The system allows for parameter changes in the lateral and rotational degrees of freedom through the linear bearing's inherent clearance, while maintaining control over the critical vertical positioning parameter. This enables the system to accommodate mechanical tolerances without sacrificing vertical positioning precision.
3Manufacturing precision
If precision vertical movement is prioritized, then layer formation accuracy is improved, but the complexity of the positioning system increases
Solution Approach 1:
The linear bearing serves as a simple intermediary component that adds minimal complexity to the system while effectively solving the rotational instability problem. Rather than requiring complex active control systems or multiple actuators, the passive linear bearing provides the necessary constraint with minimal added complexity.
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
This solution enhances the precision and speed of vertical movement in three-dimensional printing systems, improving the accuracy and efficiency of layer formation in the fabrication of solid articles by restricting rotational motion and allowing for necessary lateral adjustments, thereby improving the overall manufacturing process.
Implementation Method 1
The motorized lead screw has a vertical axis and is received into the central threaded opening of the lead screw nut. Rotation of the motorized lead screw about the vertical axis raises and lowers the lead screw nut together with the support tray elevator.
Implementation Method 2
The linear bearing slides along the main vertical support along the vertical axis. The linear bearing is coupled to the rear portion and constrains motion of the support tray elevator to linear vertical motion without rotation.
Implementation Method 3
The rear portion, the intermediate nut, and the lead screw nut form an interlocking structure. The interlocking structure constrains relative motion of the lead screw nut to the support tray elevator to restrict relative rotational motion while allowing for relative lateral motion to accommodate mechanical tolerances.
Data Source
AI summary
A three-dimensional printing system includes a vertical support beam, a resin vessel assembly coupled to the vertical support beam and including a resin vessel, and a support tray positioning system. The support tray positioning system includes a support tray elevator, a lead screw nut, a motorized lead screw, an intermediate nut, and a linear bearing. The motorized lead screw engages the lead screw nut to raise and lower the support tray elevator. The linear bearing constrains motion of the support tray elevator to vertical motion. The support tray elevator, the intermediate nut, and the lead screw nut interlock to constrain rotational motion of the lead screw nut with respect to the support tray elevator while allowing for two dimensional lateral motion of the lead screw nut with respect to the support tray elevator to accommodate mechanical tolerances of the lead screw with respect to the linear bearing.