Recoater Head Obstacle Avoidance in 3D Printing

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Solution Overview

Problem

The existing lamination molding apparatus faces challenges with recoater head damage and frequent termination of the process due to bumps in the sintered layer, leading to complex structures and difficulties in blade design and operation, resulting in unstable recoating and prolonged molding periods.

Innovation Solution

A lamination molding apparatus equipped with a servo motor-driven recoater head that transitions to a non-control state upon detecting an obstacle, allowing the recoater head to idle and prevent damage, with a controlling apparatus managing the servo motor to resume operations once the obstacle is cleared, utilizing an encoder for movement detection and an electric current detector for clashing detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the blade of the recoater head is configured to be movable to perform avoiding operation, then the recoater head can avoid damage from bumps, but the structure becomes more complicated and installation becomes extremely difficult

Engineering Contradiction:

Improverecoater head damage preventionVSAvoidrecoater head structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The blade is configured to be movable in the vertical direction through a lifting mechanism driven by a cylinder. When a bump is detected by the load cell, the blade automatically lifts to avoid contact, transforming from a static to a dynamic structure that adapts to obstacles, thus preventing damage without requiring complex reconfigurable mechanisms

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A load cell is installed to detect the load on the blade in real-time. When the load exceeds a predetermined threshold indicating bump contact, the control unit activates the cylinder to lift the blade. This feedback mechanism enables automatic avoidance operation, improving reliability while maintaining relatively simple structure through intelligent control

Inventive Principle:

Principle #23Feedback

2Reliability

If the blade performs avoiding operation after detecting load, then damage can be avoided, but the avoiding operation cannot be performed in time and the molding period is elongated

Engineering Contradiction:

Improveblade damage preventionVSAvoidmolding period

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The blade height is adjusted in advance before the recoating operation begins. The system pre-position the blade at an optimal height, and the lifting mechanism is ready to activate immediately upon bump detection. This preliminary preparation ensures that when a bump is encountered, the blade can respond instantly without delay in activation, reducing time loss while maintaining damage prevention capability

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the blade is designed to be fixed and simple, then installation becomes easier, but the recoater head cannot perform avoiding operation and is prone to damage from bumps

Engineering Contradiction:

Improveblade installationVSAvoidrecoater head damage prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

A cylinder is introduced as an intermediary mechanism between the fixed blade structure and the control system. The cylinder provides the lifting force to move the blade vertically when needed, while the blade itself remains structurally simple and easy to install. This intermediary element enables avoiding operation without complicating the blade design or installation process

Inventive Principle:

Principle #24Intermediary (Mediator)

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 prevents recoater head damage and allows for immediate resumption of the material powder layer formation, reducing the risk of blade damage and minimizing process interruptions by instantly losing torque and allowing the recoater head to idle when clashing with obstacles.

Implementation Method 1

a laser beam emitter to irradiate a laser beam to a predetermined portion of the material powder layer, thereby sintering the material powder at a position of irradiation

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

an encoder to detect a movement amount of the recoater head

Methodology Applied

Scientific EffectEncoder detection:

Implementation Method 3

a recoater head to form a material powder layer by moving in the chamber while supplying a material powder on the molding region and planarizing the material powder

Methodology Applied

Scientific EffectPlanarization:

Implementation Method 4

a servo motor to move the recoater head

Methodology Applied

Scientific EffectServo motor actuation:

Data Source

PatentUS9999925B2Three dimensional printer

Publication Date: 2018.06.19 SODICK CO LTD

AI summary

Provided is a lamination molding apparatus which can prevent the recoater head from being damaged when the recoater head clashes with an obstacle. Provided is a lamination molding apparatus including: a recoater head to form a material powder layer by moving in a chamber while supplying a material powder on a molding region and planarizing the material powder; wherein the recoater head is configured so as to be capable of being moved by a recoater head driving mechanism; the recoater head driving mechanism includes: a servo motor to move the recoater head; an encoder to detect a movement amount of the recoater head; and a controlling apparatus to control the servo motor in accordance with a value detected by the encoder; and the controlling apparatus is configured to place the servo motor in a non-control state when clashing of the recoater head with an obstacle is detected.