Six-Degree-of-Freedom Robotic Additive Manufacturing
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Solution Overview
Problem
Conventional 3D printing technologies are limited by their ability to control tools over only three degrees of freedom, leading to variations in produced parts from intended designs, increased process time, and higher costs, particularly affecting precision and accuracy requirements.
Innovation Solution
A method and system that generate robot control code for additive manufacturing tools adjustable over six degrees of freedom, involving simulation and analysis to validate and optimize the production of parts, ensuring compliance with design criteria through virtual part generation and execution by a robotic arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing controls the tool over three degrees of freedom, then the system is simpler to operate, but manufacturing precision and accuracy deteriorate
Solution Approach 1:
The patent transitions from controlling the additive manufacturing tool over three degrees of freedom to six degrees of freedom by integrating a robotic arm system. This dimensional expansion enables precise control of the tool's position and orientation in three-dimensional space, directly improving manufacturing precision and accuracy while maintaining ease of operation through automated robotic control.
2Adaptability or versatility
If additive manufacturing varies from intended part design, then adaptability increases, but manufacturing precision deteriorates
Solution Approach 1:
The patent implements simulation and analysis of the additive manufacturing process before actual production. By virtually testing and validating the manufacturing parameters, tool paths, and process conditions in advance, the system ensures that the actual production will conform to the intended part design, thereby maintaining manufacturing precision while preserving process flexibility.
Solution Approach 2:
The patent incorporates analysis of simulation results to optimize manufacturing parameters and validate process feasibility. This feedback loop allows the system to adjust and refine the additive manufacturing process to ensure part conformity to design specifications while maintaining adaptability for different part geometries and materials.
3Manufacturing precision
If simulation and analysis are performed before execution, then manufacturing precision improves, but loss of time increases
Solution Approach 1:
The patent performs simulation and analysis of the additive manufacturing process before actual execution to validate process parameters, tool paths, and part geometry. By conducting these virtual tests in advance, the system ensures high manufacturing precision and quality in the actual production, while the automated nature of the simulation minimizes the time penalty.
Data Source
AI summary
One exemplary embodiment is a method comprising generating robot control code from one or more files including part geometry parameters, material addition parameters, and robot system parameters. The robot control code includes instructions to control position and material output of an additive manufacturing tool adjustable over six degrees of freedom. The method includes simulating execution of the robot control code to generate a virtual part file including virtual part geometry parameters and material addition parameters, analyzing the virtual part geometry parameters and material addition parameters relative to the one or more files, and executing the robot control code with the controller to produce the part with robot system if the analyzing indicates that the virtual part satisfies one or more conditions.