Rotating Emitter Array Coordinate Transformation for 3D Printing Precision
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Solution Overview
Problem
Existing 3D printing methods face inefficiencies due to positioning inaccuracies and complex displacement mechanisms, leading to reduced productivity and increased wear on mechanical parts, especially when using emitters arranged in an oblique-angled coordinate system with a polar coordinate system for printing.
Innovation Solution
A method involving an emitter array with emitters arranged in an oblique-angled coordinate system, where the center points of emitters are offset in a straight line, allowing for rotational positioning and controlled activation based on geometry data, with trigger points defining material dispensing and radiation application, minimizing distortions between coordinate systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If emitters are arranged in an oblique-angled coordinate system with a polar coordinate system for printing, then the device complexity is reduced and cost-effectiveness is improved, but positioning inaccuracies occur and manufacturing precision deteriorates
Solution Approach 1:
A coordinate transformation device is introduced as an intermediary between the oblique-angled emitter array and the polar coordinate system required for printing. This device converts the coordinates of emitters in the oblique system to the polar coordinate system, enabling precise positioning without requiring complex mechanical adjustments or multiple emitter arrays. The transformation resolves the contradiction by allowing the use of a simple oblique emitter configuration while achieving the precision of a polar system through mathematical conversion.
2Manufacturing precision
If print-head carriers are displaced radially to correct irregularities, then manufacturing precision is improved, but device complexity and loss of time increase
Solution Approach 1:
The mechanical displacement of print-head carriers is replaced by a coordinate transformation approach. Instead of physically moving the emitter array or carriers to correct positioning errors, the system uses mathematical coordinate transformation to adjust the control signals sent to the emitters. This substitution eliminates the time-consuming mechanical displacement operations while maintaining positioning accuracy, as the transformation can be computed and applied instantaneously during the printing process.
3Manufacturing precision
If numerous print heads are incrementally displaced, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The complex mechanical system for incrementally displacing numerous print heads is replaced by a coordinate transformation device that operates on the control signals. The transformation device receives the geometry data and emitter positions in the oblique coordinate system and converts them to the polar coordinate system, eliminating the need for complex mechanical displacement mechanisms. This approach reduces device complexity while maintaining or improving printing accuracy through more efficient error correction.
Data Source
AI summary
In a method for producing a solid-body layer, an emitter array is provided. A support is rotationally positioned relative to the emitter array, about an axis of rotation, and material portions of a material that passes through the nozzles are applied to the support and solidified. The center point of the emitter farthest away from the axis of rotation has a first radial distance, and the emitter arranged closest to the axis of rotation has a second radial distance from the axis of rotation. A trigger signal is generated, which defines trigger points. A material dispensing signal is generated and temporarily stored, in each instance, for the individual emitters, as a function of geometry data and/or as a function of the position in which the emitter in question is arranged relative to the support, when the emitter is positioned at the corresponding trigger point. The emitters are controlled at the trigger points in such a manner that only those emitters in which the material dispensing signal is set dispense material. The angle between trigger points that are adjacent to one another corresponds to the angle that a first and a second radial line enclose between them. The first radial line runs from the axis of rotation to the intersection point between a first emitter column and a reference circle line that is concentric to the axis of rotation. The second radial line runs from the axis of rotation to the intersection point between a second emitter column and the reference circle line. The radius of the reference circle line is less than the sum of 90% of the first and 10% of the second distance. The radius is greater than the sum of 10% of the first and 90% of the second distance.