Track-Based Additive Deposition Mechanism for Large Objects
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Solution Overview
Problem
Current additive manufacturing techniques, such as stereolithography and 3-D printing, are limited by size constraints, material waste, and the need for expensive resin vats, which restrict the production of large objects and multi-material parts, and are hindered by production speed due to resin flow and curing times.
Innovation Solution
A system featuring a track-based deposition mechanism with a carriage that moves along a build platform, using a flowable resin and electromagnetic waves to solidify layers, allowing for larger object production, reduced material waste, and the ability to create multi-material parts, with an onboard power source and processor for autonomous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If vat-based techniques are used to maintain resin volume for large objects, then object size can be increased, but resin cost and maintenance cost increase significantly
Solution Approach 1:
The resin supply system is segmented into a large external reservoir and a smaller application area. The deposition mechanism retrieves resin from the external reservoir in controlled amounts, allowing large object production without requiring a proportionally large resin vat. This segmentation separates the storage function from the processing function, reducing the amount of resin that must be maintained in the build chamber at any given time.
Solution Approach 2:
The deposition mechanism acts as an intermediary between the external resin reservoir and the build platform. It controls resin flow and application, enabling precise material deposition only where needed. This intermediary system allows the use of a compact resin supply area while supporting the fabrication of large-scale objects, thereby reducing the overall resin volume required and associated costs.
2Productivity
If jet-based processes are used to deposit resin, then production speed can be increased, but resin material is wasted significantly
Solution Approach 1:
The roller-based applicator uses the viscosity and flow properties of the resin material itself to control deposition. The roller picks up resin from the supply and transfers it to the build platform through controlled rotation and pressure, allowing the material to self-regulate its flow and placement. This eliminates the need for high-speed jetting that causes overspray and waste, while maintaining efficient deposition rates.
Solution Approach 2:
The invention changes the deposition parameter from high-velocity jetting to controlled roller pressure and rotation speed. This parameter change allows resin to be deposited in a controlled, measurable manner through mechanical contact rather than aerosolization, significantly reducing material waste while maintaining acceptable production speeds for large objects.
3Productivity
If vat-based techniques submerge the object during manufacturing, then layer-by-layer production can continue, but cavities become filled with uncured resin requiring drainage and repair
Solution Approach 1:
Instead of submerging the build platform in resin as in traditional vat-based techniques, this invention inverts the approach by bringing the resin to the build platform through a controlled deposition mechanism. The roller applicator delivers resin only to the specific layer being built, leaving cavities and internal structures empty and accessible. This inversion eliminates the need for drainage holes and post-processing repairs while maintaining continuous production capability.
4Device complexity
If a single resin vat is used, then system complexity is reduced, but multi-material parts cannot be manufactured
Solution Approach 1:
The deposition mechanism is designed with universal functionality to handle multiple resin types through a single system. The roller applicator and control system can be configured to work with different resin materials, and the mechanism can switch between materials without requiring complete system redesign. This multi-functionality enables the production of multi-material parts while keeping the overall system relatively simple, avoiding the need for separate vats and deposition systems for each material.
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
Enables the production of larger three-dimensional objects with reduced material waste and increased production speed, allowing for the creation of multi-material parts and efficient use of resources, while overcoming size and speed limitations of traditional methods.
Implementation Method 1
an exposure device mounted on the carriage and configured for emitting electromagnetic waves to solidify the flowable resin
Data Source
AI summary
An apparatus for producing a three-dimensional object includes a support assembly having a build platform, a track extending through a build area, and a deposition mechanism mounted on the track and configured for producing the three-dimensional object in a layer-by-layer technique. The deposition mechanism includes a carriage moveable along the track, a supply of a flowable material mounted on the carriage, a roller in communication with the flowable material, where the roller is rotatably mounted on the carriage and configured for rotating to carry the flowable resin to an application for application to produce the object, and an exposure device mounted on the carriage. The exposure device emits electromagnetic waves to an exposure site to solidify the applied flowable material to produce the object. The roller is permeable to the electromagnetic waves, such that the waves pass through the roller in traveling from the exposure device to the exposure site.