Closed-loop Robotic Deposition for Complex 3D Geometries
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Solution Overview
Problem
Conventional 3D printers operate in an open-loop capacity, making them unable to respond to faults or deviations during the printing process, and are mechanically constrained to deposit material only in parallel, horizontal layers, limiting their ability to fabricate complex geometries such as overhanging portions.
Innovation Solution
A computer-implemented method using a robot system with a deposition tool and optical device for closed-loop control, where the robot deposits material based on real-time feedback to adjust target locations and compensate for deviations, allowing for the fabrication of complex structures with non-horizontal, non-parallel, and non-planar layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional 3D printers operate in open-loop capacity, then the printing process is simple to control, but the system cannot respond to faults or deviations during printing
Solution Approach 1:
The patent implements a closed-loop control system where sensors continuously monitor the actual deposition process and feed this information back to the controller. The controller compares actual deposition locations and material properties with target specifications, then dynamically adjusts deposition parameters to compensate for deviations, thereby achieving fault tolerance without excessive complexity.
Solution Approach 2:
The patent replaces traditional mechanical open-loop control with an integrated sensor-controller-actuator system that uses real-time data processing and adaptive algorithms. This substitution enables the system to detect and correct deviations automatically, improving reliability while managing complexity through software-based control strategies.
2Adaptability or versatility
If conventional 3D printers deposit material in parallel horizontal layers, then the printing process is mechanically simple, but the system cannot fabricate complex geometries such as overhanging portions
Solution Approach 1:
The patent employs a robotic manipulator with multiple degrees of freedom that can dynamically adjust its position and orientation during the deposition process. This dynamic capability allows the deposition tool to reach complex geometries and deposit material in non-horizontal, non-parallel layers, enabling fabrication of overhanging portions and intricate structures that static conventional printers cannot achieve.
Solution Approach 2:
The patent transitions from the constrained two-layer deposition approach of conventional printers to three-dimensional free-form deposition using a robotic system. The robotic manipulator can move in multiple dimensions and orientations, allowing material to be deposited along complex spatial paths and at various angles, thereby enabling fabrication of complex geometries including overhanging portions.
3Manufacturing precision
If a bead of material has higher than expected density, then the material properties are variable, but subsequent layers are deposited incorrectly causing the object to sag
Solution Approach 1:
The patent incorporates sensors that monitor material properties such as density, viscosity, and deposition rate in real-time. When deviations from target material properties are detected, the feedback control system dynamically adjusts deposition parameters including layer thickness, deposition speed, and curing parameters to compensate for the variations, thereby maintaining dimensional accuracy despite material property inconsistencies.
Solution Approach 2:
The patent dynamically changes deposition parameters based on real-time material property measurements. When material density varies from expected values, the system adjusts related parameters such as layer thickness, deposition rate, and curing time to compensate for the deviation, ensuring that subsequent layers are deposited correctly and preventing sagging or dimensional errors.
Data Source
AI summary
A robot system is configured to fabricate three-dimensional (3D) objects using closed-loop, computer vision-based control. The robot system initiates fabrication based on a set of fabrication paths along which material is to be deposited. During deposition of material, the robot system captures video data and processes that data to determine the specific locations where the material is deposited. Based on these locations, the robot system adjusts future deposition locations to compensate for deviations from the fabrication paths. Additionally, because the robot system includes a 6-axis robotic arm, the robot system can deposit material at any locations, along any pathway, or across any surface. Accordingly, the robot system is capable of fabricating a 3D object with multiple non-parallel, non-horizontal, and/or non-planar layers.