Rotating Binder Jet Print Head for Helical Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing systems are limited in size and efficiency due to the sequential operation of binder jet print heads and recoaters, which increases fabrication time and restricts the production of components with varying characteristics.
Innovation Solution
An additive manufacturing system with a rotating binder jet print head and a recoater assembly that allows simultaneous operation, enabling the dispensing and consolidation of particulate across a build platform using multiple print heads and a helical build process, supported by a modular structure for increased flexibility and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a binder jet print head and recoater are operated sequentially, then the system structure is simpler, but the fabrication time increases and productivity decreases
Solution Approach 1:
The patent merges the binder jet print head and recoater into a single integrated assembly that rotates together about the build platform. This allows both components to operate simultaneously on different radial positions, eliminating the sequential operation requirement and thereby reducing fabrication time while maintaining manageable system complexity through unified motion control
Solution Approach 2:
The patent transitions from linear or fixed positional operation to rotational operation about the build platform. By distributing the print head and recoater at different radial positions and rotating them together, the system enables simultaneous multi-location operation, effectively adding a rotational dimension to the build process and improving productivity
2Length of moving object
If the binder jet print head configuration is fixed, then the system is easier to manufacture, but the component size is limited
Solution Approach 1:
The patent makes the print head configuration dynamic by mounting it on a rotating assembly that can position the print head at different radial distances from the build platform center. This rotational capability allows the system to access larger build volumes and fabricate larger components without requiring a fundamentally different print head design, thereby increasing component size capability while maintaining relatively simple print head structure
Solution Approach 2:
The rotating print head assembly serves multiple functions: it can position the print head at various radial locations, rotate to access different angular positions around the build platform, and work in coordination with the recoater. This multi-functionality enables the same print head configuration to produce components of varying sizes and geometries, expanding the effective build volume without increasing print head complexity
3Loss of time
If multiple print heads operate simultaneously, then the fabrication time is reduced, but the device complexity increases
Solution Approach 1:
The patent combines multiple print heads into a single rotating assembly with the recoater, sharing common motion control mechanisms. This merging approach allows simultaneous operation of multiple print heads at different radial positions while using a unified rotation and elevation system, thereby reducing fabrication time through parallel operation without proportionally increasing device complexity
Solution Approach 2:
The rotating print head assembly enables continuous fabrication by constantly presenting active print head nozzles to different sectors of the build platform. As the assembly rotates, multiple print heads can operate simultaneously on different layers or regions, maintaining continuous productive action across the entire build volume and significantly reducing total fabrication time
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 enables the fabrication of components of any size and complexity with varying characteristics in reduced time, improving manufacturing efficiency and allowing for on-site assembly and use in remote locations.
Implementation Method 1
a plurality of print heads each having at least one binder jet. The binder jets of the plurality of print heads are configured to dispense at least one binder in varying densities onto the particulate in multiple locations to consolidate at least a portion of the particulate
Implementation Method 2
at least one actuator assembly configured to rotate at least one of the plurality of print heads and the build platform about a rotation axis extending through the build platform and move at least one of the plurality of print heads and the build platform in a build direction perpendicular to the build platform as part of a helical build process
Data Source
AI summary
An additive manufacturing system includes a build platform, a particulate dispenser assembly configured to dispense or remove particulate to or from the build platform, and a plurality of print heads each having at least one binder jet. The binder jets are configured to dispense at least one binder in varying densities onto the particulate in multiple locations to consolidate the particulate to form the component with a variable binder density throughout. The system also includes a plurality of arms extending at least partially across the build platform and supporting the print heads and at least one actuator assembly configured to rotate the print heads and/or the build platform about a rotation axis and move at least one of the print heads and the build platform in a build direction perpendicular to the build platform as part of a helical build process for the component.