Telescoping Boom 3D Printer for Large-Scale Fabrication
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Solution Overview
Problem
Existing structural three-dimensional printing technologies are limited by the reach of the boom and dipper stick, requiring frequent adjustments and being costly and slow for large-scale fabrication, especially in precision linear ways and drive mechanisms.
Innovation Solution
A structural three-dimensional printing machine with a telescoping boom and stabilizers, coupled with a controller that converts 3D printing information into positional coordinates, allowing the printhead to move efficiently across multiple axes and adjust height, enabling larger structures to be constructed with reduced effort and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a traditional boom and dipper stick system is used for 3D printing, then the printhead can be positioned within a limited reach, but the height of any structure constructed is limited and frequent adjustments are required
Solution Approach 1:
The patent applies a telescoping boom with multiple sections that can dynamically extend and retract to provide continuous vertical reach. This dynamic structure eliminates the need for frequent boom angle adjustments required in traditional fixed-length boom systems, as the telescoping sections can extend to reach higher positions while maintaining optimal angles for printing operations
Solution Approach 2:
The patent introduces an additional vertical dimension to the boom structure through telescoping sections that extend in the vertical direction. This transforms the traditional planar boom movement into a three-dimensional positioning system, allowing the printhead to access higher positions without requiring frequent repositioning of the entire boom assembly
2Productivity
If a single carriage holding one or more printheads is used for fabrication, then the system can be maneuvered within a framework, but the fabrication process is slow and limited by maneuvering speed
Solution Approach 1:
The patent divides the printing system into multiple independent carriages, each capable of holding one or more printheads. These segmented carriages can operate independently and simultaneously on different sections of the structure, eliminating the bottleneck of a single carriage that must sequentially service the entire printing area. This segmentation directly increases fabrication speed by enabling parallel printing operations
Solution Approach 2:
The patent creates a multi-functional system where multiple carriages can perform different functions simultaneously - some carriages may be dedicated to specific material types, others to different structural zones, and all can operate concurrently. This universal approach allows the system to handle diverse printing tasks in parallel, significantly improving overall productivity compared to a single-purpose carriage system
3Length of stationary object
If the machine frame remains on the ground during printing, then stability is maintained, but the telescoping boom cannot achieve sufficient height for larger structures
Solution Approach 1:
The patent employs stabilizers that can dynamically extend and retract based on the printing requirements. When the telescoping boom needs to reach greater heights for larger structures, the stabilizers extend to provide additional ground contact points, creating a stable elevated platform. This dynamic stabilization system allows the machine frame to be lifted away from the ground while maintaining stability through the extended stabilizer legs
Solution Approach 2:
The stabilizers act as intermediary elements between the machine frame and the ground when the frame is elevated. These stabilizers provide the necessary support and stability by engaging the ground at lower points while allowing the main machine frame to be positioned at a higher elevation, enabling the telescoping boom to achieve greater heights without compromising the stability of the elevated frame
Data Source
AI summary
Machines and system for 3D printing are disclosed. One machine includes a machine frame having a plurality of ground engaging elements to facilitate movement of the machine frame, a telescoping boom pivotably coupled to the machine frame and configured to pivot along at least a horizontal plane, a material line coupled to the boom and configured to convey a material therethrough, a printhead coupled to the boom and in fluid communication with the material line to receive the material and to dispense the material, and a controller configured to receive 3D printing information and to convert the 3D printing information into positional coordinates of the printhead, wherein the controller is to cause movement of the boom to position the printhead based at least on the position coordinates.