Universal Staging Platen for 3D Printing with Pin Array
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Solution Overview
Problem
Existing systems for printing on three-dimensional objects in non-production environments face challenges in adapting 2-D printing techniques to 3-D surfaces, requiring unique part holders for each object and complicating the setup process for repeated printing tasks.
Innovation Solution
A universal staging platen with a high-density array of contour pins that conform to the shape of objects under preload, allowing for repeatable and rapid acquisition and positioning of various objects for printing, using a combination of springs or elastic bands for biasing and toggle clamps for locking the pins in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If unique part holders with dedicated locating features are used for each object, then manufacturing precision of object positioning is improved, but device complexity and ease of operation deteriorate due to needing multiple custom holders
Solution Approach 1:
The patent applies universality by designing a single part holder that can accommodate multiple different objects through a standardized clamp interface. Instead of requiring unique custom holders for each object type, the system uses one versatile holder with adjustable clamping mechanisms that can securely position various objects for printing, thereby reducing device complexity while maintaining positioning precision
Solution Approach 2:
The part holder incorporates dynamic adjustment capabilities through movable clamps and positioning features that can be adapted to different object sizes and shapes. This dynamic design allows the same holder structure to maintain precise positioning for diverse objects without requiring multiple static specialized holders
2Manufacturing precision
If unique part holders are machined for each part, then manufacturing precision is improved, but ease of manufacture deteriorates due to custom machining requirements
Solution Approach 1:
The part holder design employs universal mounting features and standardized dimensions that allow a single holder design to serve multiple objects. This eliminates the need for custom machining of unique holders for each part, as the same holder can be used repeatedly with different objects secured by adjustable clamps
Solution Approach 2:
The holder design segments the positioning function into standardized mounting interfaces and adjustable clamping elements. This modular approach allows the holder to be manufactured once with generic features, while adaptability to specific objects is achieved through reconfigurable clamping components rather than custom machining
3Productivity
If 2-D printing techniques are adapted to 3-D objects, then productivity is improved by enabling on-demand printing, but ease of operation deteriorates due to complex object maneuvering requirements
Solution Approach 1:
The part holder provides dynamic positioning capabilities with adjustable clamps that can accommodate objects of various sizes and orientations. This allows operators to easily secure different objects without complex manual maneuvering, as the adjustable clamps adapt to hold the object in the correct position for printing
Solution Approach 2:
The holder design incorporates self-aligning features and gravity-assisted positioning that reduce the skill and effort required for object placement. Objects can be positioned more easily as the holder structure guides them into appropriate orientations, reducing the complexity of manual maneuvering for on-demand printing
4Device complexity
If a universal part holder is used for multiple objects, then device complexity and ease of manufacture are improved, but manufacturing precision deteriorates without dedicated locating features
Solution Approach 1:
The universal part holder maintains positioning consistency through dynamic adjustment mechanisms including movable clamps and positioning features that can be configured for each object. This allows the same holder to achieve precise, repeatable positioning for different objects by adjusting the clamping elements to match specific object geometries
Solution Approach 2:
The holder design incorporates adjustable parameters such as clamp position, clamping force, and positioning feature locations that can be modified to accommodate different objects. These parameter changes allow the universal holder to maintain consistent manufacturing precision across various objects without requiring dedicated locating features for each
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 precise and repeatable positioning of 3-D objects for printing, allowing for easy setup and efficient handling of multiple objects without the need for dedicated part holders, facilitating flexible and rapid printing operations.
Implementation Method 1
an array of pins configured to support parts for acquisition by a gripper. Once a part is placed on the array of pins, the pins conform to a shape of the part under a preload from either springs or elastic bands
Implementation Method 2
The pins are then locked into place using a clamping plate
Data Source
AI summary
A universal staging platen for many types of objects in Direct to Object printing has a datum surface which is configured to represent the plane of optimal print head distance. The universal staging platen has an array of small pins protruding from it that conform under spring load to an object placed on the datum surface. Once in a conformed state, an operator can lock the pin position so that the object is precisely positioned for acquisition by a gripper mechanism. An added benefit of locking the pin position is that subsequent copies of the object may be loaded without any additional alignment or setup. The distance the contour pins protrude through the datum surface may be adjusted so that the pin ends are sufficiently far away from the gripper mechanism being used.