Additive Manufacturing Recoat Assembly with Force Sensors
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Solution Overview
Problem
Conventional additive manufacturing systems face inconsistencies in build material distribution, leading to variation in objects built, and require frequent system downtime for recoat apparatus repair, with airborne material causing interference and degradation of system components.
Innovation Solution
A recoat assembly with a first roller supported by two roller supports, a rotational actuator, and sensors to detect forces, allowing for real-time adjustment of operating parameters and consistent material distribution, while a vacuum system contains airborne material to prevent interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional recoat apparatuses are used to distribute build material, then the additive manufacturing system can operate, but the build material distribution is inconsistent leading to variation in objects built
Solution Approach 1:
The patent incorporates sensors that detect forces incident upon the roller during build material distribution. This feedback mechanism allows the system to monitor and adjust roller operation in real-time, ensuring consistent build material distribution and eliminating variations in objects built.
Solution Approach 2:
The system adjusts operating parameters of the roller based on detected forces, dynamically changing parameters such as roller speed, pressure, or position to maintain optimal build material distribution consistency across different manufacturing conditions.
2Productivity
If conventional recoat apparatuses are used, then build material can be distributed, but system downtime increases due to frequent repair requirements
Solution Approach 1:
Sensors detect forces incident upon the roller and provide real-time feedback to the control system. This enables early detection of abnormal conditions that could lead to component breakage, allowing for preventive maintenance adjustments that reduce system downtime and improve reliability.
Solution Approach 2:
The system automatically adjusts operating parameters based on sensor feedback without requiring manual intervention or repair. This self-adjusting capability reduces the frequency of repairs needed and minimizes system downtime.
3Productivity
If conventional recoat apparatuses fluidize build material for distribution, then material can be spread, but airborne build material disperses to other components causing interference and degradation
Solution Approach 1:
The system contains airborne build material that would otherwise be harmful to other components. By converting this potentially harmful byproduct of fluidization into a contained element, the system maintains the benefits of efficient material distribution while eliminating the degradation of other system components.
Data Source
AI summary
A recoat assembly for an additive manufacturing system includes a first roller support, a second roller support, a first roller disposed between and supported by the first roller support and the second roller support, a first rotational actuator operably coupled to the first roller and configured to rotate the first roller about a first rotation axis, and a first sensor mechanically coupled to and in contact with the first roller support, where the first sensor outputs a first output signal indicative of a first force incident upon the first roller.