Rotating Support 3D Printing with Offset Emitter Array
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Solution Overview
Problem
Existing 3D printing methods are inefficient due to the need for stopping and accelerating the print-head module, which wastes time and causes mechanical stress leading to wear and reduced precision, especially on smaller to medium-sized printed surfaces.
Innovation Solution
A method utilizing an emitter array with emitters arranged in an oblique-angled, straight-line coordinate system, where print dots are assigned to emitters and print cycles based on geometry data, allowing for continuous rotation and offsetting to maintain consistent layer thickness and print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the print-head module is stopped and accelerated between layers, then the material application can be precisely controlled, but the printing time increases and mechanical wear increases
Solution Approach 1:
The support is pre-positioned at predetermined angular positions before material application. By preparing the support position in advance and maintaining continuous rotation, the system eliminates stopping and starting between layers, thereby increasing printing speed while maintaining precision through pre-planned positioning.
Solution Approach 2:
The support rotates continuously throughout the printing process without stopping. Material is applied at specific angular positions during this continuous rotation, allowing the printing process to proceed without interruption. This continuous motion eliminates the time loss and mechanical stress associated with repeated stopping and acceleration.
2Manufacturing precision
If the print-head module is stopped and accelerated frequently, then layer-by-layer precision is maintained, but mechanical stress increases causing wear
Solution Approach 1:
The continuous rotation of the support eliminates repeated stopping and starting, thereby reducing mechanical stress on drive components. The system maintains reliability by keeping the rotation continuous while still achieving precise layer-by-layer material application through controlled dispensing at specific angular positions.
3Productivity
If the support rotates continuously without stopping, then printing speed increases, but precise positioning for each layer becomes more difficult
Solution Approach 1:
An encoder detects the angular position of the support during continuous rotation and provides feedback signals. This feedback enables the control system to identify predetermined angular positions accurately and trigger material application at the correct moments, thereby maintaining positioning precision despite continuous motion.
Solution Approach 2:
The support serves dual functions: it acts as both the platform for material application and the rotating element that enables continuous processing. By integrating the support's rotational motion with the printing process, the system achieves both high speed and precise positioning through coordinated control.
Data Source
AI summary
In a method for producing at least one solid-body layer on a support that can be rotated about an axis of rotation, in accordance with predetermined geometry data, an emitter array having a plurality of emitters configured as material-dispensing nozzles is provided, which nozzles are arranged in emitter columns and emitter rows. Emitter columns that are adjacent to one another in the circumferential direction of an axis of rotation are offset from one another, in the expanse direction of the emitter columns, in each instance, in such a manner that the emitters are arranged at different radial distances DA(i) from the axis of rotation. It holds true that: DA(i) DA(i+1). Print dots are assigned to the geometry data, which dots are offset from one another, in a matrix having multiple rows that run next to one another, in such a manner that it holds true that: PA(j)>PA(j+1), wherein PA(j) is the radial distance of the jth print dot Pj of the row in question from the axis of rotation. For print dots Pk for which material is supposed to be dispensed onto the support, at least one material portion, in each instance, is dispensed from the emitter Dk of the emitter array assigned to the print dot Pk in question. Dispensing of the material portions takes place in print cycles in which the emitter array is triggered to dispense material once, in each instance, at a trigger point assigned to the print cycle in question, in each instance, and the support as well as the emitter array are offset relative to one another, from print cycle to print cycle, in each instance, by an angular distance with reference to the axis of rotation. Printing of all the print dots of a row takes place in a number of print cycles that is greater than the number of emitter columns. The print cycle is selected, for each print dot to be printed, in each instance, in such a manner that the angular difference between the rotational position of the trigger point of the print cycle and the rotational position in which the print dot to be printed is arranged with reference to the axis of rotation when the support is positioned at the trigger point relative to the emitter array is not greater, in terms of amount, than half the angular distance between the trigger points.