Stacker Module Registration Pins for 3D Composite Printing
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Solution Overview
Problem
In automated three-dimensional composite-based additive manufacturing, achieving precise sheet-to-sheet registration during the stacking of substrate sheets is challenging, leading to potential inaccuracies and failures in the formation of 3D objects.
Innovation Solution
A stacker apparatus with registration holes on each sheet, precisely aligned with the printed layer images, uses tapered registration pins to ensure accurate alignment, allowing for some misregistration tolerance and simplifying the precision requirements of other machine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If registration holes are precisely aligned with printed layer images using fixed punching apparatus, then sheet-to-sheet registration precision is improved, but machine complexity and precision requirements for other components increase
Solution Approach 1:
The patent introduces registration holes as an intermediary feature that mediates between the punching apparatus and the final registration accuracy. These holes serve as a reference system that decouples the precision requirements from the main positioning mechanism, allowing other components to be less precise while maintaining overall registration accuracy through the hole-based reference system.
Solution Approach 2:
The registration system is segmented into discrete registration holes punched at specific locations on each sheet. This segmentation allows the registration function to be separated from the overall sheet handling system, enabling independent optimization of the punching operation while other components can operate with relaxed precision tolerances.
2Ease of operation
If tapered registration pins are used to accommodate misregistration, then tolerance for sheet placement and punching is relaxed, but the complexity of the registration mechanism increases
Solution Approach 1:
The registration pins are designed with a tapered geometry parameter change, transitioning from a smaller diameter at the top to a larger diameter at the base. This parameter variation allows the pin to accommodate misregistered sheets during insertion while maintaining precise registration once the sheet is properly positioned, effectively providing tolerance without requiring complex adjustment mechanisms.
3Manufacturing precision
If precise alignment is required during sheet placement and punching, then registration accuracy is improved, but the difficulty of operation and time consumption increase
Solution Approach 1:
The registration holes are punched in advance as a preliminary action during the printing process. This preliminary creation of reference features eliminates the need for complex real-time alignment operations later, as the holes already provide the registration reference needed for stacking. The preliminary punching action simplifies subsequent operations by providing a ready-made reference system.
Data Source
AI summary
A stacker component of an apparatus for automated manufacturing of three-dimensional composite-based objects for aligning registration of sheets. The stacker includes a sheet catcher; a frame having a base plate with the base plate having tapered registration pins to align a stack of substrate sheets. The registration pins are mounted in the base plate and project vertically to a location just below the sheet catcher. The stacker also has a presser with a press plate and a belt driver system that moves the press plate up and down allowing the press plate to exert downward pressure on the stack and a slide system with two guide rails that enable the base plate to be loaded and unloaded. A conveyor can be disposed so that after a substrate sheet exits a powder or printing system, the sheet is conveyed onto the sheet catcher.