Closed-Loop Robotic Deposition for Non-Planar 3D Printing
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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 and adjustments to target locations, 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 that continuously monitors the actual deposition location and compares it to the target location. The system uses feedback from the monitored deposition process to dynamically adjust and update target locations, enabling the system to respond to deviations and maintain printing reliability despite variations in material properties or environmental conditions.
2Adaptability or versatility
If conventional 3D printers deposit material in parallel horizontal layers, then the printing mechanism is mechanically simple, but the system cannot fabricate complex geometries such as overhanging portions
Solution Approach 1:
The patent transforms the static, fixed-layer deposition approach into a dynamic system where target locations are continuously updated based on actual deposition feedback. This dynamic adaptation allows the system to deposit material in non-horizontal, non-parallel layers and fabricate complex geometries including overhanging portions, while maintaining a relatively simple mechanical deposition mechanism.
Solution Approach 2:
The patent extends the deposition capability from strictly horizontal layers to three-dimensional spatial deposition. By updating target locations in all three dimensions based on feedback, the system can create complex geometries that require deposition in multiple orientations and angles, effectively adding dimensional flexibility without complex mechanical reconfiguration.
3Manufacturing precision
If a bead of material has higher than expected density, then the material properties are more robust, but the bead takes longer to harden causing subsequent layers to be deposited incorrectly
Solution Approach 1:
The patent performs preliminary detection of deposition location and material characteristics before completing the deposition of subsequent layers. By monitoring the hardening process and detecting deviations in real-time, the system can identify when a bead is taking longer than expected to harden and adjust subsequent deposition parameters or target locations accordingly, preventing dimensional inaccuracies before they occur.
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.