Removable Build Modules for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing systems lack flexibility and speed, often requiring high user interaction for material handling and cleaning, leading to time delays between print jobs and interruptions in continuous use.
Innovation Solution
The development of removably insertable build modules with modular designs that allow for different sizes and configurations, enabling faster use and minimizing interruptions by facilitating quick cleaning and simultaneous printing across multiple modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional additive manufacturing systems are used with fixed build chambers, then manufacturing precision and quality can be maintained, but productivity is reduced due to time delays between print jobs and frequent user interaction for material handling and cleaning
Solution Approach 1:
The build chamber is divided into multiple removable build modules, each capable of independent operation. This segmentation allows one module to be prepared or cleaned while another is in use, eliminating idle time and enabling continuous printing operations without waiting for single-chamber preparation or cleaning cycles.
Solution Approach 2:
Build modules can be pre-prepared with materials and pre-cleaned in advance before being installed in the system. This preliminary preparation of modules eliminates the need for time-consuming material handling and cleaning operations during the printing process, thereby reducing time delays between print jobs.
2Manufacturing precision
If traditional additive manufacturing systems require high user interaction for material handling and cleaning, then manufacturing precision can be maintained through direct control, but ease of operation deteriorates due to frequent interruptions
Solution Approach 1:
The system enables automated module preparation and cleaning operations without requiring continuous user intervention. Build modules can be automatically loaded with materials, positioned, and cleaned by the system itself, reducing the frequency of user interactions while maintaining precision through controlled automated processes.
3Adaptability or versatility
If single build chamber systems are used, then device complexity is reduced, but adaptability deteriorates due to inability to accommodate different sizes and configurations
Solution Approach 1:
The build chamber is segmented into multiple standardized modules that can be arranged in different configurations. This modular architecture provides adaptability for different print job requirements while managing complexity through standardization of module interfaces and designs.
Solution Approach 2:
The build modules are designed with universal interfaces and standardized dimensions, allowing the same module type to serve multiple functions and be arranged in various configurations. This universality provides system adaptability without proportionally increasing device complexity, as the same modular components can be reused in different arrangements.
Data Source
Figure 1a~1c
Figure 2a~2d
Figure 2e~3
AI summary
A build module is provided. The build module may include a housing and a build material chamber in the housing to hold build material. The build module may include a build chamber in the housing. The build material chamber may be beneath the build chamber or next to the build chamber. The build chamber may include a moveable support member to receive successive layers of the build material from a build material distributor. The build module may be removably insertable into a build receiver of an additive manufacturing system to allow the additive manufacturing system to solidify a portion the successive layers to be received onto the movable support member.