Single-Gantry Near-Net-Shape 3D Printing With Integrated Trimming
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Solution Overview
Problem
Conventional additive manufacturing machines with separate printing and trimming gantries are costly and unsuitable for smaller machines, increasing machine size and complexity, and the process of melting thin filaments for 3D printing is slow for large items.
Innovation Solution
A single-gantry machine design that integrates both printing and trimming operations, allowing for near net shape additive manufacturing, with a fixed gantry and movable work table, and includes a print head and trim head supported on the same gantry, enabling efficient production of larger parts without the need for dual gantries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate printing and trimming gantries are used, then printing and trimming operations can be performed independently, but machine size and complexity increase
Solution Approach 1:
The patent combines both printing and trimming operations onto a single gantry system. The gantry supports both a print head for additive manufacturing and a trim head for post-processing operations, allowing both functions to be performed on one machine without requiring separate gantries, thereby reducing machine size and complexity while maintaining operational independence through sequential processing
2Device complexity
If a single gantry is used for both printing and trimming, then machine size and costs are reduced, but the machine must perform multiple operations sequentially
Solution Approach 1:
The patent implements a movable work table that can be repositioned under the single gantry to accommodate different operation phases. The work table moves horizontally to position the part under either the print head or trim head as needed, enabling flexible sequential operations while maintaining a compact single-gantry structure. This dynamic repositioning allows the machine to efficiently switch between printing and trimming without requiring separate fixed gantries
3Manufacturing precision
If thin filament melting process is used, then detailed and precise printing is achieved, but production speed is slow for large items
Solution Approach 1:
The patent performs trimming operations immediately after printing each layer or section while the material is still relatively warm and pliable. This preliminary trimming action removes excess material before it fully solidifies, allowing for faster material removal and reducing the need for extensive post-processing. The trim head operates sequentially with the print head, maintaining precision while improving overall production speed for large items
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
The integrated machine reduces costs and space requirements while enabling faster production of larger components by combining printing and trimming processes, suitable for both horizontal and vertical printing configurations.
Implementation Method 1
a process of melting a thin layer of thermoplastic material, and applying this material in layers to produce a final part
Implementation Method 2
passing a continuous thin filament of thermoplastic material through a heated nozzle, which melts the material and applies it to the structure being printed
Implementation Method 3
Traditional print heads may include an oscillating plate surrounding the nozzle, the plate being configured to oscillate vertically to flatten the bead of material against the surface or part on which the bead is deposited
Data Source
AI summary
An additive manufacturing apparatus includes a first vertically-extending support leg, a second vertically-extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus also includes a work table movably supported beneath the gantry, a print head supported on the gantry, and a trim head supported on the gantry with the print head.