APPARATUS FOR UNIFORM COMPRESSION OF ADDITIVE MANUFACTURING SUBSTRATES

Abstract

Abstract Disclosed is a consolidation apparatus comprising a pair of press units disposed vertically to secure an additive manufacturing substrate, with each press unit comprising an adaptive cushion and a peripheral framework surrounding the adaptive cushion. An adjustable bracket attaches to the peripheral framework through connector beams, and a securing connector couples to the adjustable bracket to maintain uniform compression across the additive manufacturing substrate. Dated 11 November 2024 Jigneshbhai Mungalpara IN/PA- 2640 Agent for the Applicant

Specification

Description:Apparatus for Uniform Compression of Additive Manufacturing Substrates
Field of the Invention
[0001] The present disclosure generally relates to additive manufacturing apparatuses. Further, the present disclosure particularly relates to consolidation apparatuses with press units for uniform compression of additive manufacturing substrates.
Background
[0002] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Additive manufacturing processes have gained significant importance due to their ability to create complex structures by depositing successive material layers to form an object. Such processes are frequently used in various fields, including automotive, aerospace, and medical device manufacturing. While additive manufacturing offers several advantages, there remains a need to improve the precision and uniformity of materials within each layer, which affects the quality and structural integrity of manufactured components. The quality of components fabricated through additive manufacturing significantly depends on various factors, including consolidation pressure and temperature control applied to the substrate during manufacturing. Conventional apparatuses frequently face challenges in maintaining adequate pressure uniformity, which is essential to ensure a high degree of material fusion and structural consistency across the layers.
[0004] In conventional additive manufacturing consolidation apparatuses, two common techniques are used to secure substrates and apply pressure. The first technique relies on single-sided pressing units, which compress only one side of the substrate during the additive manufacturing process. Such single-sided pressing methods often result in uneven pressure distribution across the substrate, which reduces the structural integrity of fabricated components. Furthermore, single-sided pressing units are prone to displacement and instability during operation, leading to misalignment, which further affects the overall quality of the manufactured component.
[0005] Another common technique involves the use of opposing pressing units that secure the substrate from both sides to create a more balanced compression. While dual-sided pressing methods improve pressure distribution, conventional designs frequently use rigid frameworks or fixed components. Such rigid frameworks are limited in adaptability, which restricts their ability to adjust to substrates with varying thicknesses or material properties. Consequently, substrates that do not fit precisely within the fixed framework may experience inconsistent pressure or movement during manufacturing, causing flaws in the additive layers and reducing the durability of the final product. Furthermore, the inflexibility of such rigid pressing systems results in increased setup time and requires precise calibration to accommodate different substrates, which complicates the manufacturing process and reduces overall efficiency.
[0006] Additional known techniques involve the use of mechanical connectors or securing mechanisms to hold the substrate in place within the pressing apparatus. However, such mechanical connectors often lack effective means for real-time adjustment or adaptability during the manufacturing process. In conventional systems, securing connectors are commonly used to stabilize the substrate, but they may loosen or fail to maintain compression consistently over time. Such inconsistencies lead to variations in the additive manufacturing process, which can result in defects or weak points within the manufactured component. Moreover, mechanical connectors employed in conventional systems are generally rigid, making them susceptible to wear and deterioration over prolonged use, thereby reducing the operational lifespan of the apparatus.
[0007] Other state-of-the-art systems utilise pneumatic or hydraulic pressing units to apply force to the substrate. While such systems offer higher pressure capacity, they are often complex, costly, and require continuous maintenance to ensure consistent performance. Pneumatic and hydraulic systems also involve higher energy consumption and have limited responsiveness to pressure fluctuations or changes in substrate dimensions during manufacturing. Furthermore, such systems often contribute to vibrations and other forms of operational instability, which may negatively impact layer deposition and lead to compromised quality in the additive manufacturing process.
[0008] In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for improving uniformity and adaptability in the consolidation of substrates in additive manufacturing processes.
[0009] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
Summary
[00010] Various objects, features, and advantages of the disclosed subject matter can be more fully appreciated with reference to the following detailed description of the disclosed subject matter when considered in connection with the following drawings, in which like reference numerals identify like elements.
[00011] The present disclosure generally relates to additive manufacturing apparatuses. Further, the present disclosure particularly relates to consolidation apparatuses with press units for uniform compression of additive manufacturing substrates.
[00012] An objective of the present disclosure is to provide a consolidation apparatus that enables uniform compression of an additive manufacturing substrate, improving stability, alignment, and adaptability to varied substrate thicknesses. The system of the present disclosure aims to achieve enhanced substrate conformity to reduce deformation, maintain structural integrity, and support precision in additive manufacturing.
[00013] In an aspect, the present disclosure provides a consolidation apparatus comprising a pair of vertically disposed press units to secure an additive manufacturing substrate. Each press unit comprises an adaptive cushion surrounded by a peripheral framework, while an adjustable bracket attaches to the framework via connector beams. A securing connector is coupled to the adjustable bracket to maintain consistent compression.
[00014] Furthermore, the apparatus achieves uniform force distribution through connector beams aligned linearly to distribute force evenly across the adaptive cushion, enhancing stability in substrate compression. Enhanced stability also results from the adaptive cushion's perimeter contacting the peripheral framework, counteracting lateral displacement. Additionally, the apparatus supports synchronized movement through an adjustable hinge, facilitating cohesive force distribution during vertical compression cycles.
[00015] Further adaptability is provided by a rotational axis on the securing connector, allowing for varied compression settings to improve conformity to different substrate materials. A sliding track on the adjustable bracket further enables positional adjustments, enhancing contact precision between the adaptive cushion and substrate. The apparatus additionally incorporates a spring-loaded tension mechanism within the connector beams for controlled elasticity, preserving surface integrity under varying compressive forces. Furthermore, a shock-absorbent layer beneath the adaptive cushion reduces vibration, increasing operational stability. Finally, an elastomeric spacer between adjacent press units provides additional lateral support, improving compression uniformity by preventing substrate misalignment.
Brief Description of the Drawings
[00016] The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
[00017] FIG. 1 illustrates a consolidation apparatus (100), in accordance with the embodiments of the present disclosure.
[00018] FIG. 2 illustrates a sequential diagram of the consolidation apparatus (100), in accordance with the embodiments of the present disclosure.
Detailed Description
[00019] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.
[00020] In view of the many possible embodiments to which the principles of the present discussion may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the claims. Therefore, the techniques as described herein contemplate all such embodiments as may come within the scope of the following claims and equivalents thereof.
[00021] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items.
[00022] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00023] The present disclosure generally relates to additive manufacturing apparatuses. Further, the present disclosure particularly relates to consolidation apparatuses with press units for uniform compression of additive manufacturing substrates.
[00024] Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
[00025] As used herein, the term "consolidation apparatus" refers to any system or device constructed to apply uniform compression to a substrate during an additive manufacturing process. Said apparatus comprises at least two press units disposed in a vertical orientation relative to one another to secure a substrate used in manufacturing. Such a consolidation apparatus includes various structural elements to ensure the uniform application of compressive force and is particularly effective in maintaining substrate stability during compression. The consolidation apparatus may further be adapted for use in diverse manufacturing environments requiring uniform pressure distribution across various substrate materials. Additionally, said apparatus may be applicable in industries involving layer-by-layer manufacturing processes, including automotive and aerospace. The consolidation apparatus may thus include other elements or configurations necessary for efficient, accurate substrate securing during compression, enabling consistency in layer formation. Furthermore, said apparatus may provide a stable interface for materials sensitive to pressure or vibration variations in the additive manufacturing context.
[00026] As used herein, the term "press units" refers to structural components of the consolidation apparatus that apply compressive force to secure an additive manufacturing substrate. Said press units are disposed in a vertical alignment and comprise various internal features enabling efficient distribution of force across the substrate during compression. Each press unit includes an adaptive cushion and is supported by a surrounding peripheral framework to stabilize the compression process. The press units are particularly adapted for maintaining alignment with the substrate, which is essential for creating uniform layers in additive manufacturing applications. Such press units can be constructed from materials selected for durability and resistance to wear during repeated compression cycles. The press units, therefore, form a fundamental component in ensuring uniform application of force across the substrate surface, contributing to improved layer adhesion and structural integrity of the resulting manufactured component.
[00027] As used herein, the term "additive manufacturing substrate" refers to any material layer or base that serves as the foundation for sequential material deposition in an additive manufacturing process. The additive manufacturing substrate serves as the primary base upon which layers are formed to create a final structure or component. In various embodiments, said substrate can be fabricated from materials suited to the intended manufacturing process, including metals, polymers, or composites. The substrate's structural integrity is maintained through compression applied by press units within the consolidation apparatus, which supports the even distribution of material layers across said substrate. Furthermore, the substrate may vary in thickness or material composition based on manufacturing requirements. Such an additive manufacturing substrate is vital for enabling uniform layer construction and achieving structural precision in the finished product, particularly in high-demand manufacturing environments such as aerospace and automotive industries.
[00028] As used herein, the term "adaptive cushion" refers to a resilient material component within each press unit that supports uniform distribution of compression force across the additive manufacturing substrate. Said adaptive cushion conforms to the shape of the substrate during compression, reducing potential points of excessive pressure and maintaining the substrate's structural integrity. The adaptive cushion may comprise materials such as elastomers or composites that allow for controlled deformation under applied force, ensuring contact between the press unit and the substrate. Such an adaptive cushion is positioned within each press unit and is surrounded by the peripheral framework to contain and stabilize the compressive force. The cushion's adaptive properties allow for effective compression across substrates of varied dimensions and thicknesses, enhancing the precision of layer application in additive manufacturing processes by maintaining substrate alignment.
[00029] As used herein, the term "peripheral framework" refers to the structural boundary surrounding the adaptive cushion within each press unit. Said peripheral framework provides support and containment for the cushion during compression cycles, ensuring the cushion remains aligned with the substrate to prevent displacement. The peripheral framework is positioned to enclose the adaptive cushion, creating a secure boundary that limits lateral movement of said cushion. Constructed from rigid or semi-rigid materials, the peripheral framework is designed to withstand repeated cycles of compression while maintaining alignment between the cushion and the substrate. In an embodiment, the peripheral framework may also incorporate additional elements to enhance stability, allowing for reliable compression performance in additive manufacturing applications. Such a framework supports consistent force application, which is crucial for maintaining the precision and quality of layered structures within manufacturing processes.
[00030] As used herein, the term "adjustable bracket" refers to a movable structural component attached to the peripheral framework of the press units to facilitate position adjustments during compression. Said adjustable bracket connects to the peripheral framework through a set of connector beams, enabling positional shifts that support optimal alignment of the press units with the additive manufacturing substrate. The adjustable bracket can slide or adjust its position relative to the framework, allowing for dynamic alignment in response to variations in substrate dimensions or material properties. Constructed from durable materials, the adjustable bracket enables precise alignment control within the consolidation apparatus, which is essential for maintaining uniform compression. The adjustability of said bracket further enhances adaptability to different substrate requirements, ensuring the press units maintain stable contact with the substrate throughout the compression cycle.
[00031] As used herein, the term "connector beams" refers to structural members that attach the adjustable bracket to the peripheral framework of the press units, providing a secure linkage for the compression system. Said connector beams extend perpendicularly from the peripheral framework and are affixed to a central point of the adjustable bracket, ensuring a linear alignment with the press units. Such an arrangement enables balanced force distribution across the adaptive cushion, facilitating even compression across the additive manufacturing substrate. The connector beams are constructed from robust materials to withstand repeated compressive forces while maintaining alignment between the bracket and the framework. Additionally, the connector beams may incorporate mechanisms for tension adjustment or other features that enhance stability, making them suitable for precision manufacturing processes where alignment consistency is essential for high-quality output.
[00032] As used herein, the term "securing connector" refers to a structural component that couples the adjustable bracket to maintain uniform compression across the additive manufacturing substrate. Said securing connector is attached to the adjustable bracket and functions as a stabilizing mechanism that helps maintain constant pressure on the substrate during compression. The securing connector may be positioned to interact with the adjustable bracket along a rotational axis, enabling adjustments that accommodate variations in substrate material or thickness. Constructed from materials with high strength and durability, the securing connector helps to retain consistent compression alignment, ensuring that the additive manufacturing substrate remains stable throughout the layering process. Such a securing connector is essential in maintaining the reliability of the consolidation apparatus, especially in manufacturing applications requiring controlled force distribution across varying substrate types.
[00033] FIG. 1 illustrates a consolidation apparatus (100), in accordance with the embodiments of the present disclosure. In an embodiment, a pair of press units 102 is provided within the consolidation apparatus 100. Each of the press units 102 is disposed vertically in relation to the other, forming a spaced alignment to secure an additive manufacturing substrate 104. Said press units 102 apply compressive force to said additive manufacturing substrate 104 to stabilize and hold the substrate in a fixed position during additive manufacturing. Each press unit 102 includes an adaptive cushion 106 positioned within the press unit 102 and a peripheral framework 108 that surrounds the adaptive cushion 106. The adaptive cushion 106 may be constructed from a resilient material that deforms in response to applied force, allowing it to conform to the shape and surface irregularities of the additive manufacturing substrate 104. Such an adaptive cushion 106 provides enhanced contact with the surface of the substrate, which minimizes potential displacement of the substrate during the manufacturing process. The peripheral framework 108, enclosing the adaptive cushion 106, serves as a stabilizing boundary that restricts excessive lateral or vertical movement of the adaptive cushion 106. In various implementations, the peripheral framework 108 may include rigid structural elements positioned around the adaptive cushion 106 to maintain consistent force distribution across the cushion and substrate. The vertical arrangement of the press units 102 is beneficial in providing balanced compression, as the upper and lower units exert force evenly across the substrate's surface, maintaining alignment and structural integrity during the application of additive layers.
[00034] In an embodiment, an adjustable bracket 110 is provided within the consolidation apparatus 100 and is attached to the peripheral framework 108 of each press unit 102. Said adjustable bracket 110 functions as a movable connection that allows for precise positional adjustments of each press unit 102 relative to the substrate 104. Said adjustable bracket 110 is connected to the peripheral framework 108 by a series of connector beams 112, which extend from the framework to attach securely to the bracket. The adjustable bracket 110 may allow controlled linear or angular movement, facilitating alignment of the press units 102 with the substrate 104. Said adjustable bracket 110 can shift positions as necessary to account for variations in substrate thickness, material properties, or other manufacturing conditions that require customized adjustments in compression. Such a bracket may incorporate sliding or pivoting elements, allowing the press units 102 to shift along a defined path, ensuring continuous contact with the substrate 104 during compression. Said adjustable bracket 110 is constructed from durable materials to withstand the compressive forces exerted by the press units 102, thus preserving the stability and integrity of the apparatus 100. In various embodiments, the adjustable bracket 110 may include alignment markers or locking mechanisms to maintain a consistent and reproducible position after adjustments have been made.
[00035] In an embodiment, a securing connector 114 is coupled to the adjustable bracket 110 within the consolidation apparatus 100 to maintain uniform compression across the additive manufacturing substrate 104. Said securing connector 114 acts as a stabilizing link that provides consistent alignment and compressive force during the manufacturing process. The securing connector 114 may be attached to the adjustable bracket 110 at a defined point, ensuring that each press unit 102 remains in position as intended. Said securing connector 114 can include a hinge or flexible coupling that permits minor positional adjustments to accommodate changes in substrate orientation or material requirements. In some embodiments, the securing connector 114 is aligned parallel to the connector beams 112 to maintain a balanced distribution of force across the adaptive cushion 106 and the substrate 104. Said connector 114 may be rotatably or pivotally attached to the adjustable bracket 110, enabling controlled rotational adjustments that allow for realignment based on substrate dimensions or weight distribution.
[00036] In an embodiment, each of the connector beams 112 extends perpendicularly from the peripheral framework 108 and affixes at a central point of the adjustable bracket 110. Such a perpendicular alignment of the connector beams 112 establishes a precise linear arrangement between the adjustable bracket 110 and the press units 102. This configuration distributes

force uniformly across the adaptive cushion 106, which is crucial for maintaining balanced compression across the entire surface of the additive manufacturing substrate 104. By connecting at the central point of the adjustable bracket 110, each connector beam 112 provides a stable linkage that resists rotational displacement, thus preventing variations in compression that might otherwise impact structural integrity. Each connector beam 112 may be constructed of materials with high strength and minimal flex to withstand the forces generated during compression cycles without deformation. In some embodiments, the length of each connector beam 112 can be adjusted to accommodate different substrate dimensions, thereby enhancing the versatility of the consolidation apparatus 100 for substrates of various sizes. Additionally, the perpendicular alignment of the connector beams 112 relative to the peripheral framework 108 enhances the rigidity of the overall structure and helps maintain consistent contact between the press units 102 and the adaptive cushion 106. Such a configuration is beneficial in applications requiring precise and uniform force distribution across varying thicknesses or material properties in the substrate 104, thereby enabling high-quality, repeatable layer formation in additive manufacturing processes.
[00037] In an embodiment, the adaptive cushion 106 is positioned within each press unit 102, with its perimeter in direct contact with the peripheral framework 108. This positioning of the adaptive cushion 106 allows for secure containment within the peripheral framework 108, effectively counteracting lateral displacement during compression. By ensuring that the adaptive cushion 106 remains enclosed by the surrounding framework 108, the press units 102 maintain consistent alignment with the additive manufacturing substrate 104 throughout each compression cycle. In various implementations, the adaptive cushion 106 may be composed of a resilient material capable of deforming under applied pressure, which aids in accommodating minor surface irregularities on the substrate 104. The secure containment provided by the peripheral framework 108 minimizes undesired movement of the adaptive cushion 106, which is essential for maintaining even contact with the substrate surface. Such an arrangement is particularly beneficial in applications where high-precision alignment is required to achieve consistent layer thickness across the substrate 104. By stabilizing the adaptive cushion 106 within the press unit 102, this configuration also enables greater control over the compressive force exerted, which is vital in processes requiring uniform layer application across substrates with varied thicknesses.
[00038] In an embodiment, each press unit 102 is configured to operate in conjunction with the securing connector 114 through an adjustable hinge. The adjustable hinge facilitates synchronized movement of each press unit 102 relative to the vertical axis of the additive manufacturing substrate 104, ensuring cohesive force distribution throughout the compression process. Such a hinge allows each press unit 102 to maintain alignment with the substrate 104 as compressive forces are applied, reducing the risk of misalignment and uneven pressure distribution. In some configurations, the adjustable hinge may include locking mechanisms or tension controls, allowing precise adjustments to be made in response to variations in substrate dimensions or material properties. By permitting controlled movement, the hinge enhances the versatility of the press units 102, enabling them to adapt to the specific requirements of different substrates while maintaining a uniform compression profile. The adjustable hinge may be constructed from durable materials with high resistance to wear, ensuring long-lasting stability and reliability in repeated cycles. The hinge's adjustable nature also allows for gradual realignment of the press units 102 if any shift in position occurs during operation, thereby ensuring consistent compression across the entire substrate surface.
[00039] In an embodiment, the securing connector 114 is affixed to the adjustable bracket 110 through a rotational axis that is parallel to the connector beams 112. The rotational axis allows for rotational adjustments of the securing connector 114, which facilitates customized compression settings across the adaptive cushion 106. Such adjustments enable the consolidation apparatus 100 to adapt its compression force to the specific requirements of different substrate materials, which may vary in hardness, thickness, or other properties. The rotational axis allows the securing connector 114 to pivot or rotate in response to external forces, maintaining consistent contact with the substrate 104 while allowing the press units 102 to conform to the surface of the substrate. In some configurations, the securing connector 114 may incorporate a locking mechanism along the rotational axis, allowing the position to be fixed once the desired compression settings are achieved. This feature is particularly beneficial for applications requiring high consistency in force distribution, as it ensures that the substrate 104 remains firmly secured without excessive movement or pressure fluctuations.
[00040] In an embodiment, the adjustable bracket 110 interlocks with the peripheral framework 108 along a sliding track, which allows for reciprocal movement parallel to the axis of the press units 102. Such a sliding track enables dynamic positional adjustment of the adjustable bracket 110, which enhances contact precision between the adaptive cushion 106 and the additive manufacturing substrate 104. The sliding track may include guide rails or grooves that restrict movement to a single linear path, thereby ensuring that the adjustable bracket 110 remains aligned with the press units 102 throughout the compression process. By allowing movement parallel to the press units' axis, the sliding track enables the adaptive cushion 106 to adjust its position as needed to maintain consistent pressure across substrates of varying thicknesses. In some embodiments, the sliding track may include locking mechanisms or tension-adjustment features to secure the adjustable bracket 110 in the desired position once optimal contact has been achieved.
[00041] In an embodiment, each connector beam 112 incorporates a spring-loaded tension adjustment mechanism that provides controlled elasticity between the peripheral framework 108 and the adjustable bracket 110. This spring-loaded mechanism enables incremental adjustments to the tension applied by each connector beam 112, which is beneficial for accommodating variances in substrate dimensions or material properties. The elasticity provided by the spring-loaded adjustment mechanism allows the press units 102 to respond dynamically to variations in compressive force, thereby preserving the surface integrity of the additive manufacturing substrate 104. Each spring-loaded mechanism may include a calibrated spring or adjustable tension element that allows fine-tuning of the force exerted by each connector beam 112. Such controlled elasticity is essential for maintaining consistent compression, as it prevents overloading or underloading of the substrate 104, which could result in defects or misalignment during the additive manufacturing process.
[00042] In an embodiment, the peripheral framework 108 encompasses a shock-absorbent layer positioned beneath the adaptive cushion 106. The shock-absorbent layer provides a secondary cushion that mitigates the transmission of vibrations between the press units 102 and the additive manufacturing substrate 104. By reducing vibrations, the shock-absorbent layer stabilizes the compression environment and enhances the durability of the consolidation apparatus 100 during repeated compression cycles. Such a layer may be constructed from elastomeric or viscoelastic materials with high damping properties, allowing it to absorb and dissipate energy generated by the compression process. In various embodiments, the shock-absorbent layer may include multiple layers or materials with differing damping characteristics, enabling tailored vibration control to suit the specific requirements of the manufacturing environment.
[00043] In an embodiment, each press unit 102 in the consolidation apparatus 100 is vertically spaced from an adjacent press unit by an elastomeric spacer. Said elastomeric spacer is configured to dampen lateral displacement of the additive manufacturing substrate 104 within the securing connector 114. The elastomeric spacer absorbs lateral forces that may arise during compression, preventing undesired movement or misalignment of the substrate 104 within the press units 102. Such a spacer may be constructed from materials with high elasticity and resilience, enabling it to deform under lateral loads and return to its original shape without compromising stability. The elastomeric spacer's ability to dampen lateral movement is beneficial for maintaining uniform compression across the substrate 104, particularly in applications where precise alignment is required for high-quality layer formation.
[00044] FIG. 2 illustrates a sequential diagram of the consolidation apparatus (100), in accordance with the embodiments of the present disclosure. The illustrated consolidation apparatus 100 includes a pair of vertically disposed press units 102 designed to secure an additive manufacturing substrate 104 by applying compressive force from both the top and bottom. Each press unit 102 houses an adaptive cushion 106, which adjusts to the substrate's surface, providing consistent contact and pressure. Surrounding each adaptive cushion 106 is a peripheral framework 108 that stabilizes and restricts lateral movement of the cushion, enhancing alignment and pressure uniformity. The peripheral framework 108 connects to an adjustable bracket 110 via connector beams 112, enabling precise positioning of each press unit 102. A securing connector 114 attaches to the adjustable bracket 110, maintaining the bracket's stability and ensuring consistent compression across the substrate 104. The entire arrangement works cohesively to stabilize the substrate during compression, supporting uniform layer application and structural integrity in additive manufacturing processes.
[00045] In an embodiment, the consolidation apparatus 100 comprises a pair of press units 102 disposed vertically to secure an additive manufacturing substrate 104. The vertical arrangement of the press units 102 provides balanced compression, as both units apply force from opposing directions, which maintains the stability and alignment of the substrate 104 during compression. Each press unit 102 includes an adaptive cushion 106 and a peripheral framework 108 surrounding the cushion 106. The adaptive cushion 106 adapts to minor irregularities on the substrate surface, ensuring complete contact and reducing gaps that could lead to uneven compression. The peripheral framework 108 encloses the adaptive cushion 106, restricting its movement and preventing lateral displacement during the compression process. This containment structure enhances the durability of the cushion 106 and allows consistent application of pressure across the entire substrate. Such a configuration enables the apparatus 100 to apply uniform compression, improving layer consistency and structural integrity of the manufactured substrate.
[00046] In an embodiment, each connector beam 112 extends perpendicularly from the peripheral framework 108 and is affixed at a central point of the adjustable bracket 110. This perpendicular alignment establishes a linear configuration with the press units 102, ensuring that force is evenly distributed across the adaptive cushion 106. The central affixation of the connector beams 112 to the adjustable bracket 110 stabilizes the compression system, reducing potential rotational or lateral misalignments that could arise during operation. The perpendicular orientation of the connector beams 112 also prevents uneven force distribution, which could result in localized stress points on the substrate 104. By facilitating equal force transmission across the adaptive cushion 106, this arrangement enhances stability and achieves uniform pressure application throughout the substrate, thereby improving structural consistency and reducing the risk of deformation or misalignment.
[00047] In an embodiment, the adaptive cushion 106 is positioned within each press unit 102, with its perimeter in direct contact with the peripheral framework 108. This direct contact provides a secure containment that restricts lateral displacement of the adaptive cushion 106 during compression cycles. The containment offered by the peripheral framework 108 stabilizes the adaptive cushion 106, maintaining alignment with the substrate 104 even under varying compressive forces. This configuration is particularly beneficial for substrates of varied thicknesses, as it allows the cushion 106 to adapt while maintaining contact precision. Such an arrangement enhances the ability of the apparatus 100 to deliver consistent, high-precision compression across the substrate surface, which is essential for ensuring uniform layer formation and preventing defects associated with misalignment or irregular force distribution.
[00048] In an embodiment, each press unit 102 operates in conjunction with the securing connector 114 through an adjustable hinge, which allows synchronized movement of the press units 102 relative to the vertical axis of the additive manufacturing substrate 104. The adjustable hinge permits controlled movement of the press units 102, maintaining their alignment with the substrate throughout the compression cycle. This synchronized operation ensures that force is applied evenly from both sides, enhancing the uniformity of substrate compression. The hinge allows each press unit 102 to adapt to slight variations in substrate positioning, reducing the likelihood of uneven compression. By preserving cohesive force distribution across the substrate surface, this configuration improves substrate stability and ensures a consistent layer application, which is vital for high-quality additive manufacturing outcomes.
[00049] In an embodiment, the securing connector 114 is affixed to the adjustable bracket 110 through a rotational axis that is parallel to the connector beams 112. This parallel orientation allows the securing connector 114 to make rotational adjustments, facilitating customized compression settings across the adaptive cushion 106. Such rotational capability enables the apparatus 100 to adapt the compression force in response to varying substrate materials, which may have different rigidity or surface characteristics. By allowing the securing connector 114 to rotate, the apparatus achieves better conformity between the cushion 106 and the substrate 104, ensuring stable contact across the substrate surface. This adaptability reduces gaps and inconsistencies in pressure application, enhancing material stability and structural integrity of the final product.
[00050] In an embodiment, the adjustable bracket 110 interlocks with the peripheral framework 108 along a sliding track, enabling reciprocal movement parallel to the axis of the press units 102. This sliding track provides dynamic positional adjustment, allowing the adjustable bracket 110 to shift as needed to maintain optimal contact between the adaptive cushion 106 and the additive manufacturing substrate 104. The parallel movement facilitated by the sliding track ensures that compression levels can be finely tuned to prevent substrate deformation. Such adjustability is especially beneficial for substrates of differing thicknesses, as it allows the apparatus 100 to maintain consistent pressure without overloading or underloading the substrate, thus ensuring uniform compression and improved layer quality in additive manufacturing processes.
[00051] In an embodiment, each connector beam 112 incorporates a spring-loaded tension adjustment mechanism that provides controlled elasticity between the peripheral framework 108 and the adjustable bracket 110. This mechanism allows incremental adjustments to the tension in each connector beam 112, accommodating variances in substrate thickness or material properties. The controlled elasticity provided by the spring-loaded mechanism enables the press units 102 to respond dynamically to changes in compressive force, thus preserving the surface integrity of the substrate 104. This configuration is particularly effective in preventing excessive force on delicate substrates, reducing the risk of surface damage. By allowing for tension adjustments, the mechanism also contributes to consistent compression, ensuring that the substrate remains stable under varying load conditions during the manufacturing process.
[00052] In an embodiment, the peripheral framework 108 encompasses a shock-absorbent layer positioned beneath the adaptive cushion 106, providing a secondary cushioning effect that mitigates vibration transmission between the press units 102 and the substrate 104. This shock-absorbent layer minimizes the impact of mechanical vibrations, which can disrupt layer alignment and compromise the quality of the manufactured product. By absorbing vibrations, the layer stabilizes the compression environment, allowing for more consistent contact between the cushion 106 and the substrate. The vibration-damping effect also reduces wear on the press units 102 and the substrate 104, thereby enhancing the operational lifespan and durability of the apparatus 100, particularly in applications involving repeated compression cycles.
[00053] In an embodiment, each press unit 102 in the apparatus 100 is vertically spaced from an adjacent press unit by an elastomeric spacer, which is configured to dampen lateral displacement of the substrate 104 within the securing connector 114. The elastomeric spacer absorbs lateral forces that may arise during compression, preventing undesired movement or misalignment of the substrate. Such damping improves compression uniformity by ensuring that the substrate remains in the correct position throughout the compression process. Constructed from high-elasticity materials, the elastomeric spacer can deform under load and then return to its original shape, providing a stabilizing effect that enhances alignment precision and minimizes the risk of defects in the layered structure of the substrate.
[00054] Further, while operations are depicted in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Likewise, while several specific implementation details are contained in the above discussions, these should not be construed as limitations on the scope of the subject matter described herein, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
[00055] The term "memory," as used herein relates to a volatile or persistent medium, such as a magnetic disk, or optical disk, in which a computer can store data or software for any duration. Optionally, the memory is non-volatile mass storage such as physical storage media. Furthermore, a single memory may encompass and in a scenario wherein computing system is distributed, the processing, memory and/or storage capability may be distributed as well.
[00056] Throughout the present disclosure, the term 'server' relates to a structure and/or module that include programmable and/or non-programmable components configured to store, process and/or share information. Optionally, the server includes any arrangement of physical or virtual computational entities capable of enhancing information to perform various computational tasks.
[00057] Throughout the present disclosure, the term "network" relates to an arrangement of interconnected programmable and/or non-programmable components that are configured to facilitate data communication between one or more electronic devices and/or databases, whether available or known at the time of filing or as later developed. Furthermore, the network may include, but is not limited to, one or more peer-to-peer network, a hybrid peer-to-peer network, local area networks (LANs), radio access networks (RANs), metropolitan area networks (MANS), wide area networks (WANs), all or a portion of a public network such as the global computer network known as the Internet, a private network, a cellular network and any other communication system or systems at one or more locations.
[00058] Throughout the present disclosure, the term "process"* relates to any collection or set of instructions executable by a computer or other digital system so as to configure the computer or the digital system to perform a task that is the intent of the process.
[00059] Throughout the present disclosure, the term 'Artificial intelligence (AI)' as used herein relates to any mechanism or computationally intelligent system that combines knowledge, techniques, and methodologies for controlling a bot or other element within a computing environment. Furthermore, the artificial intelligence (AI) is configured to apply knowledge and that can adapt it-self and learn to do better in changing environments. Additionally, employing any computationally intelligent technique, the artificial intelligence (AI) is operable to adapt to unknown or changing environment for better performance. The artificial intelligence (AI) includes fuzzy logic engines, decision-making engines, preset targeting accuracy levels, and/or programmatically intelligent software.













other digital system so as to configure the computer or the digital system to perform a task that is the intent of the process.
[00059] Throughout the present disclosure, the term 'Artificial intelligence (AI)' as used herein relates to any mechanism or computationally intelligent system that combines knowledge, techniques, and methodologies for controlling a bot or other element within a computing environment. Furthermore, the artificial intelligence (AI) is configured to apply knowledge and that can adapt it-self and learn to do better in changing environments. Additionally, employing any computationally intelligent technique, the artificial intelligence (AI) is operable to adapt to unknown or changing environment for better performance. The artificial intelligence (AI) includes fuzzy logic engines, decision-making engines, preset targeting accuracy levels, and/or programmatically intelligent software.

Claims
I/We Claim:
1. A consolidation apparatus (100) comprising:
a pair of press units (102) disposed vertically to secure an additive manufacturing substrate (104), wherein each of said press units (102) comprising an adaptive cushion (106) and a peripheral framework (108) surrounding the cushion (106);
an adjustable bracket (110) attached to the peripheral framework (108) via connector beams (112);
and a securing connector (114) coupled to the adjustable bracket (110) to maintain uniform compression.
Claim 2
Each of said connector beams (112) extending perpendicularly from said peripheral framework (108) and affixed at a central point of said adjustable bracket (110), establishing a linear alignment with said press units (102) to distribute equal force across said adaptive cushion (106), enhancing stability and ensuring uniform pressure application throughout said additive manufacturing substrate (104) for increased structural integrity.
Claim 3
Said adaptive cushion (106) positioned within each press unit (102) with its perimeter in direct contact with said peripheral framework (108), enabling a secure containment that counteracts lateral displacement during compression, thereby enhancing the alignment of said press units (102) with said additive manufacturing substrate (104) for consistent, high-precision application across varied thicknesses of substrates.
Claim 4
Each of said press units (102) configured to operate in conjunction with said securing connector (114) through an adjustable hinge, facilitating synchronized movement of said press units (102) relative to the vertical axis of said additive manufacturing substrate (104) and maintaining cohesive force distribution for enhanced uniformity in substrate compression without variation in press alignment.
Claim 5
Said securing connector (114) affixed to said adjustable bracket (110) through a rotational axis parallel to said connector beams (112), facilitating rotational adjustments that enable customized compression settings across said adaptive cushion (106), allowing the apparatus (100) to adapt compression force in response to different substrate materials, thereby improving substrate conformity to the cushion's surface for enhanced material stability.
Claim 6
Said adjustable bracket (110) interlocking with said peripheral framework (108) along a sliding track, enabling reciprocal movement parallel to the axis of said press units (102) and ensuring dynamic positional adjustment that enhances the contact precision between said adaptive cushion (106) and said additive manufacturing substrate (104), thereby optimizing compression levels to prevent deformation.
Claim 7
Each of said connector beams (112) incorporating a spring-loaded tension adjustment mechanism to facilitate controlled elasticity between said peripheral framework (108) and said adjustable bracket (110), allowing for incremental adjustments to accommodate substrate variances, which preserves surface integrity of said additive manufacturing substrate (104) under varying compressive forces.
Claim 8
Said peripheral framework (108) further encompassing a shock-absorbent layer positioned beneath said adaptive cushion (106), providing a secondary cushion layer that mitigates vibration transmission between said press units (102) and said additive manufacturing substrate (104), thus improving operational stability during compression cycles for enhanced durability of said apparatus (100).
Claim 9
Each press unit (102) in said apparatus (100) is vertically spaced from an adjacent press unit by an elastomeric spacer configured to dampen lateral displacement of said additive manufacturing substrate (104) within said securing connector (114), preventing substrate misalignment and enhancing compression uniformity during operation.




Dated 11 November 2024 Jigneshbhai Mungalpara
IN/PA- 2640
Agent for the Applicant



Apparatus for Uniform Compression of Additive Manufacturing Substrates
Abstract
Disclosed is a consolidation apparatus comprising a pair of press units disposed vertically to secure an additive manufacturing substrate, with each press unit comprising an adaptive cushion and a peripheral framework surrounding the adaptive cushion. An adjustable bracket attaches to the peripheral framework through connector beams, and a securing connector couples to the adjustable bracket to maintain uniform compression across the additive manufacturing substrate.


Dated 11 November 2024 Jigneshbhai Mungalpara
IN/PA- 2640
Agent for the Applicant





, Claims:other digital system so as to configure the computer or the digital system to perform a task that is the intent of the process.
[00059] Throughout the present disclosure, the term 'Artificial intelligence (AI)' as used herein relates to any mechanism or computationally intelligent system that combines knowledge, techniques, and methodologies for controlling a bot or other element within a computing environment. Furthermore, the artificial intelligence (AI) is configured to apply knowledge and that can adapt it-self and learn to do better in changing environments. Additionally, employing any computationally intelligent technique, the artificial intelligence (AI) is operable to adapt to unknown or changing environment for better performance. The artificial intelligence (AI) includes fuzzy logic engines, decision-making engines, preset targeting accuracy levels, and/or programmatically intelligent software.

Claims
I/We Claim:
1. A consolidation apparatus (100) comprising:
a pair of press units (102) disposed vertically to secure an additive manufacturing substrate (104), wherein each of said press units (102) comprising an adaptive cushion (106) and a peripheral framework (108) surrounding the cushion (106);
an adjustable bracket (110) attached to the peripheral framework (108) via connector beams (112);
and a securing connector (114) coupled to the adjustable bracket (110) to maintain uniform compression.
Claim 2
Each of said connector beams (112) extending perpendicularly from said peripheral framework (108) and affixed at a central point of said adjustable bracket (110), establishing a linear alignment with said press units (102) to distribute equal force across said adaptive cushion (106), enhancing stability and ensuring uniform pressure application throughout said additive manufacturing substrate (104) for increased structural integrity.
Claim 3
Said adaptive cushion (106) positioned within each press unit (102) with its perimeter in direct contact with said peripheral framework (108), enabling a secure containment that counteracts lateral displacement during compression, thereby enhancing the alignment of said press units (102) with said additive manufacturing substrate (104) for consistent, high-precision application across varied thicknesses of substrates.
Claim 4
Each of said press units (102) configured to operate in conjunction with said securing connector (114) through an adjustable hinge, facilitating synchronized movement of said press units (102) relative to the vertical axis of said additive manufacturing substrate (104) and maintaining cohesive force distribution for enhanced uniformity in substrate compression without variation in press alignment.
Claim 5
Said securing connector (114) affixed to said adjustable bracket (110) through a rotational axis parallel to said connector beams (112), facilitating rotational adjustments that enable customized compression settings across said adaptive cushion (106), allowing the apparatus (100) to adapt compression force in response to different substrate materials, thereby improving substrate conformity to the cushion's surface for enhanced material stability.
Claim 6
Said adjustable bracket (110) interlocking with said peripheral framework (108) along a sliding track, enabling reciprocal movement parallel to the axis of said press units (102) and ensuring dynamic positional adjustment that enhances the contact precision between said adaptive cushion (106) and said additive manufacturing substrate (104), thereby optimizing compression levels to prevent deformation.
Claim 7
Each of said connector beams (112) incorporating a spring-loaded tension adjustment mechanism to facilitate controlled elasticity between said peripheral framework (108) and said adjustable bracket (110), allowing for incremental adjustments to accommodate substrate variances, which preserves surface integrity of said additive manufacturing substrate (104) under varying compressive forces.
Claim 8
Said peripheral framework (108) further encompassing a shock-absorbent layer positioned beneath said adaptive cushion (106), providing a secondary cushion layer that mitigates vibration transmission between said press units (102) and said additive manufacturing substrate (104), thus improving operational stability during compression cycles for enhanced durability of said apparatus (100).
Claim 9
Each press unit (102) in said apparatus (100) is vertically spaced from an adjacent press unit by an elastomeric spacer configured to dampen lateral displacement of said additive manufacturing substrate (104) within said securing connector (114), preventing substrate misalignment and enhancing compression uniformity during operation.




Dated 11 November 2024 Jigneshbhai Mungalpara
IN/PA- 2640
Agent for the Applicant

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