Horizontal WAAM Layout With Rotating Build Plate and Multi-Robot Deposition
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Solution Overview
Problem
Conventional wire arc additive manufacturing (WAAM) systems are limited by vertical print orientation, which restricts the size of printed objects, requires special facilities, and leads to unevenness due to gravity effects, limiting flexibility and accessibility.
Innovation Solution
Implementing a horizontal print orientation for WAAM systems with a rotating build plate and multiple robots, allowing for consistent gravity force and improved accessibility, enabling faster print speeds and better quality with larger scale and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical print orientation is used for WAAM, then gravity acts uniformly on each layer, but the size of printed objects is restricted and special facilities are required
Solution Approach 1:
The patent inverts the conventional vertical print orientation to a horizontal print orientation. By rotating the build plate 90 degrees, the system prints layers horizontally rather than vertically stacking layers. This inversion allows for larger printed objects without requiring tall enclosures, while the build plate rotation maintains consistent gravity action on the molten material during deposition.
Solution Approach 2:
The patent introduces a rotatable build plate that can dynamically adjust its orientation. The build plate rotates during the printing process to maintain optimal positioning and consistent gravity action on the deposited material. This dynamic adjustment allows the system to achieve both large object sizes and uniform gravity effects throughout the printing process.
2Shape
If vertical print orientation is used for WAAM, then layers are stacked height-wise, but accessibility and flexibility are reduced
Solution Approach 1:
The patent inverts the conventional vertical layer stacking to horizontal layer deposition. Instead of stacking layers in the height-wise direction, the system deposits layers horizontally along the length of the build plate. This inversion dramatically improves accessibility, allowing operators to easily access the printed object from all sides without requiring specialized facilities or complex retrieval mechanisms.
3Ease of operation
If horizontal print orientation is implemented, then accessibility and flexibility improve, but consistent gravity force must be maintained
Solution Approach 1:
The patent employs a dynamically rotatable build plate that maintains consistent orientation relative to gravity during horizontal printing. The build plate rotates to ensure the build surface remains horizontal, providing consistent gravity action on the deposited material while allowing the printed object to grow in the horizontal direction. This dynamic adjustment maintains reliability while achieving improved accessibility.
Solution Approach 2:
The patent separates the build direction from the gravity direction by introducing a rotational degree of freedom. The build plate rotates around the vertical axis, allowing the build surface to remain horizontal (consistent with gravity) while the printed object extends in horizontal dimensions. This dimensional separation enables both consistent gravity force and improved accessibility.
4Productivity
If multiple robots operate concurrently on a rotating build plate, then throughput increases, but coordination complexity increases
Solution Approach 1:
The patent makes the build plate a universal reference frame for multiple robots. All robots coordinate their movements and deposition operations relative to the rotating build plate's position and orientation. This universal reference system simplifies the coordination complexity by providing a common frame of reference, allowing multiple robots to operate concurrently with improved throughput while managing complexity through standardized coordination protocols.
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
Horizontal WAAM systems achieve higher throughput, improved surface finish, and reduced complexity, enabling the printing of large-scale metal parts with increased accessibility and flexibility, without the need for tall enclosures or special facilities.
Implementation Method 1
gravity generally acts on each point of a layer uniformly
Implementation Method 2
heat energy is applied to the metal wire and the heat energy melts the wire to allow it to be layered
Implementation Method 3
wire arc additive manufacturing (WAAM) is a production process used to 3D print and/or repair metal parts
Data Source
AI summary
Systems and methods for wire arc additive manufacturing systems that print in horizontal orientations are described. Horizontal WAAM 3D print systems comprise metal 3D print systems in a horizontal orientation with one or more robots operating concurrently on a work piece using one or more wire feeds and a rotating, horizontal build plate.