Purge Tower Additive Manufacturing Automation
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Solution Overview
Problem
Conventional additive manufacturing systems require a separate purge station for extruding part or support material, which reduces the usable build volume and inhibits fully automated operation due to the need for material consumption and manual intervention in emptying purge buckets.
Innovation Solution
The method involves printing a purge tower using both part and support materials during the purge operation, allowing each print head to achieve the necessary purge functions without a separate purge station, thereby increasing the usable build volume and enabling fully automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate purge station is used for extruding material, then the purge function is achieved, but the usable build volume is reduced and manual intervention is required
Solution Approach 1:
The patent merges the purge function with the main printing operation by using the same print head and build volume for both purposes. The purge tower is printed within the existing build volume alongside the part and support structure, eliminating the need for a separate purge station and maximizing the usable build volume.
Solution Approach 2:
The print head is designed to perform multiple functions: printing the part, printing support structure, and performing purge operations. The same extrusion system is used for all material deposition tasks, including the purge tower, which serves both as a purge mechanism and as part of the overall printed structure.
2Reliability
If a separate purge station is used, then material purging is achieved, but fully automated operation is inhibited due to manual emptying requirements
Solution Approach 1:
The purge tower is designed to be self-contained and integrated into the printed structure. As the print head extrudes material for the purge tower, it automatically purges the extrusion system. The tower remains attached to the build plate and is removed with the printed part, eliminating the need for manual intervention to empty purge buckets and enabling fully automated operation.
3Reliability
If a separate purge station is used, then purge operations are performed, but device complexity increases
Solution Approach 1:
The patent combines the purge station functionality with the main printing system. The same print head, extrusion system, and build plate are used for both printing and purging operations. The purge tower is printed as part of the overall structure, eliminating the need for separate hardware components and reducing system complexity.
4Reliability
If purge towers are printed using part material, then purge function is achieved, but material consumption increases
Solution Approach 1:
The patent changes the material parameter by using support material instead of part material for printing the purge tower. This parameter change reduces material consumption because support material is typically used in greater quantities and is removed after printing, whereas part material is a valuable consumable. The support material serves dual purposes: providing structural support and enabling purge operations.
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 approach eliminates the need for a separate purge station, reduces material consumption, and allows for fully automated operation of the additive manufacturing system, enhancing its efficiency and scalability.
Implementation Method 1
The extruded part material fuses to previously deposited part material, and solidifies upon a drop in temperature.
Implementation Method 2
The extruded part material fuses to previously deposited part material, and solidifies upon a drop in temperature.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A method for printing a three-dimensional part (20) with an additive manufacturing system (10), the method including printing layers of the three-dimensional part (20) and of a support structure (22) for the three-dimensional part (20) from multiple print heads (18) or deposition lines, and switching the print heads (18) or deposition line between stand-by modes and operating modes in-between the printing of the layers of the three-dimensional part (20) and the support structure (22). The method also includes performing a purge operation for each print head (18) or deposition line switched to the operating mode, where the purge operation includes printing a layer of at least one purge tower (24) from the print head (18) or deposition line switched to the operating mode.