Closed-Loop Robotic Deposition for Fault-Tolerant 3D Fabrication
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Solution Overview
Problem
Conventional 3D printers operate in an open-loop capacity, unable to respond to feedback or deviations during the printing process, leading to faults and limitations in fabricating complex geometries with overhanging portions or varying layer orientations.
Innovation Solution
A computer-implemented method using a robot system with a deposition tool and optical device for closed-loop control, where real-time feedback from video data is processed to adjust deposition locations and guide curves, allowing for compensation of deviations and deposition of material along non-horizontal, non-parallel, and non-planar layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional 3D printers operate in open-loop capacity, then the printing process is simple and fast, but the system cannot respond to feedback or deviations during printing
Solution Approach 1:
The patent implements a closed-loop control system where an optical device captures video data of the deposition process, and a software application processes this data to determine actual deposition locations. The system then compares actual locations with target locations and adjusts subsequent deposition operations accordingly, enabling real-time feedback and correction of printing deviations.
2Adaptability or versatility
If conventional 3D printers deposit material in substantially parallel horizontal layers, then the printing process is mechanically simple, but the printer cannot fabricate objects with overhanging portions or complex geometries
Solution Approach 1:
The patent employs a robotic deposition tool with multiple degrees of freedom that can dynamically adjust its position and orientation in three-dimensional space. Unlike conventional printers with fixed linear motion, this robotic system can deposit material along complex spatial paths including overhanging portions and non-planar surfaces, enabling fabrication of diverse geometries.
Solution Approach 2:
The system transitions from conventional two-dimensional layer-by-layer deposition to three-dimensional spatial deposition. The robotic deposition tool can move freely in X, Y, and Z dimensions and adjust its deposition angle, allowing material to be placed at any location and orientation within the build volume, not just in horizontal layers.
3Manufacturing precision
If closed-loop control with real-time feedback is implemented, then the system can compensate for deviations and tolerate faults, but the processing and control complexity increases
Solution Approach 1:
The patent implements a closed-loop control system where an optical device captures video data of the deposition process, and a software application processes this data to determine actual deposition locations. The system then compares actual locations with target locations and adjusts subsequent deposition operations accordingly, enabling real-time feedback and correction of printing deviations.
Solution Approach 2:
The system performs self-correction by automatically detecting deposition deviations through video analysis and adjusting subsequent deposition operations without external intervention. The software application autonomously processes video data, calculates position errors, and modifies the deposition plan to compensate for accumulated deviations, enabling the system to print accurate geometries despite process variations.
Data Source
AI summary
A robot system is configured to fabricate three-dimensional (3D) objects using closed-loop, computer vision-based control. The robot system initiates fabrication based on a set of fabrication paths along which material is to be deposited. During deposition of material, the robot system captures video data and processes that data to determine the specific locations where the material is deposited. Based on these locations, the robot system adjusts future deposition locations to compensate for deviations from the fabrication paths. Additionally, because the robot system includes a 6-axis robotic arm, the robot system can deposit material at any locations, along any pathway, or across any surface. Accordingly, the robot system is capable of fabricating a 3D object with multiple non-parallel, non-horizontal, and/or non-planar layers.