An automatic nozzle cleaning and anti-clogging device and method for 3D printers

Abstract

This invention provides an automatic nozzle cleaning and anti-clogging device and method for 3D printers, which uses a combination of high-pressure airflow and a heating system for cleaning. The high-pressure airflow is used to impact residual material inside the nozzle, while the heating system is used to soften and remove substances adhering to the inner wall of the nozzle. This system not only effectively prevents nozzle clogging but also maintains the nozzle in optimal working condition, reducing printing interruptions caused by clogging.

Description

Technical Field

[0001] This invention relates to the field of 3D printing technology, and in particular to an automatic nozzle cleaning and anti-clogging device and method for 3D printers. Background Technology

[0002] 3D printers, as a cutting-edge manufacturing technology, have demonstrated unique advantages in numerous industries, including medical, aerospace, and automotive manufacturing. However, nozzle clogging remains a significant challenge in practical use. Common causes of nozzle clogging include insufficient melting of the printing material, impurities in the material, and uneven cooling rates. These problems not only affect print quality but can also lead to print job interruptions, reducing production efficiency and product consistency.

[0003] Currently, the main methods for resolving nozzle clogging problems include manually cleaning the nozzles and replacing them. However, these methods have the following limitations:

[0004] (1) Manual cleaning of nozzles: Although it can solve the clogging problem, this method is complicated and time-consuming, especially when frequent cleaning is required, which greatly affects production efficiency.

[0005] (2) Replace the nozzle: Although replacing the nozzle can restore normal printing, it involves downtime and material waste, and the new nozzle may also have similar problems. Summary of the Invention

[0006] In view of this, the purpose of the present invention is to provide an automatic nozzle cleaning and anti-clogging device and method for 3D printers, which monitors and maintains the nozzle status in real time through intelligent detection and automatic cleaning technology, thereby improving the efficiency and print quality of 3D printing and reducing production interruptions and maintenance costs caused by nozzle clogging.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: an automatic nozzle cleaning and anti-clogging device for a 3D printer, comprising a nozzle cleaning module, an intelligent sensing module, and a control system module; the nozzle cleaning module and the intelligent sensing module are connected to the control system module; the nozzle cleaning module includes an adjustable airflow system and a controllable heating system, which automatically adjust the airflow intensity and heating temperature according to different material types and environmental conditions to effectively remove residual materials and solidified substances from the nozzle;

[0008] The intelligent sensing module is used to detect the nozzle temperature, pressure, material flow, and material properties. When a risk of clogging is detected, the intelligent sensing module transmits a signal to the control system module, which then activates the nozzle cleaning module to perform a cleaning operation and dynamically adjusts the cleaning program to ensure optimal cleaning effect and print quality.

[0009] In a preferred embodiment, the nozzle cleaning module includes a high-pressure airflow system and a controllable heating system. An intelligent sensing module monitors the nozzle temperature and material flow state. The high-pressure airflow system is used to clean residual material inside the nozzle by airflow, while the heating system is used to remove solidified material by adjusting the temperature.

[0010] In a preferred embodiment, the intelligent sensing module includes a temperature sensor with a response time of 0.1 seconds and a monitoring accuracy of ±0.5℃. It is suitable for different printing materials with nozzle temperatures ranging from 180℃ to 450℃, and common 3D printing materials include PLA, ABS, PEEK, etc.

[0011] In a preferred embodiment, the intelligent sensing module further includes a pressure sensor, a material humidity sensor, and a particle monitoring sensor, used to monitor the temperature, pressure changes, and material properties of the nozzle in real time, and to determine whether there is a risk of nozzle blockage.

[0012] In a preferred embodiment, the material humidity sensor monitors the humidity of the feed material with an accuracy of ±1%, ensuring that the material humidity remains within a set range to prevent nozzle clogging caused by increased adhesion due to material moisture. The particle monitoring sensor is used to detect the particle size of the material, ensuring that the material particles entering the nozzle are evenly distributed. The particle size monitoring accuracy can reach ±0.01 mm, adapting to the printing needs of different types of materials.

[0013] This invention also provides an automatic nozzle cleaning and anti-clogging method for 3D printers, which employs the aforementioned automatic nozzle cleaning and anti-clogging device for 3D printers, and includes the following steps:

[0014] (1) Monitor the temperature, pressure, material flow state and material properties inside the nozzle, including humidity and particle size;

[0015] (2) When the intelligent sensing module detects a risk of blockage, it automatically pauses printing and starts a cleaning program;

[0016] (3) Adjust the high-pressure airflow intensity and heating system temperature in the nozzle cleaning module according to the detected degree of blockage to clean the residual materials and solidified substances inside the nozzle;

[0017] (4) After cleaning, the nozzle calibration program is automatically executed to ensure that the nozzle is in normal condition, and then the printing process is resumed to ensure print quality.

[0018] Compared with existing technologies, this invention has the following advantages: the device uses a combination of high-pressure airflow and a heating system for cleaning. The high-pressure airflow is used to impact residual material inside the nozzle, while the heating system is used to soften and remove substances adhering to the inner wall of the nozzle. This system not only effectively prevents nozzle clogging but also maintains the nozzle in optimal working condition, reducing printing interruptions caused by clogging. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall device according to a preferred embodiment of the present invention;

[0020] Figure 2 This is a flowchart illustrating a preferred embodiment of the present invention. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0023] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations according to this application; as used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise; furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0024] An automatic nozzle cleaning and anti-clogging device for a 3D printer includes a nozzle cleaning module, an intelligent sensing module, and a control system module; the nozzle cleaning module and the intelligent sensing module are connected to the control system module. It can automatically adjust the airflow intensity and heating temperature according to different material types (such as PLA, ABS, PETG, etc.) and environmental conditions (such as temperature and humidity) to effectively remove residual materials and solidified substances from the nozzle.

[0025] The intelligent sensing module is used to detect the nozzle temperature, pressure, material flow, and material properties (such as humidity and particle size). When a risk of clogging is detected, the intelligent sensing module transmits a signal to the control system module, which then activates the nozzle cleaning module to perform a cleaning operation and dynamically adjusts the cleaning program to ensure optimal cleaning effect and print quality.

[0026] in:

[0027] Nozzle Cleaning Module: The nozzle cleaning module includes a high-pressure airflow system and a controllable heating system. An intelligent sensing module can monitor nozzle temperature and material flow status with precise response speed and high accuracy. The high-pressure airflow system cleans residual material inside the nozzle, while the heating system eliminates solidified material by adjusting the temperature. The temperature sensor has a response time of 0.1 seconds and a monitoring accuracy of ±0.5℃, suitable for various printing materials with nozzle temperatures ranging from 180℃ to 450℃. The intelligent sensing module can adapt to materials with different melting points, such as PLA, ABS, and PETG, in real time to ensure smooth material flow within the nozzle and promptly detect flow abnormalities to prevent clogging. This module cleans residual material inside the nozzle by heating, combined with the high-pressure airflow system for internal nozzle cleaning, enabling rapid and effective removal of accumulated printing material. The high-pressure airflow system operates at a pressure of 2-4 bar and a flow rate of 100 L / min, suitable for printing environments with different materials and temperatures. The cleaning time is automatically adjusted based on sensor data to minimize material residue.

[0028] The intelligent sensing module includes temperature and pressure sensors, enabling real-time monitoring of temperature changes and material flow within the nozzle during printing. When the sensors detect obstructed material flow or abnormal temperature, a cleaning procedure is automatically triggered. The intelligent sensing module employs a high-sensitivity temperature sensor with a response time of 0.1 seconds, suitable for a temperature range of 200℃-400℃, adapting to the melting point requirements of different materials, and accurately determining whether abnormal material flow has occurred. The material humidity sensor monitors the feed humidity with an accuracy of ±1%, ensuring that the material humidity remains within the set range to prevent nozzle clogging caused by increased adhesion due to material moisture. The particle size monitoring sensor detects the particle size of the material, ensuring uniform particle distribution upon entering the nozzle, with a particle size monitoring accuracy of ±0.01 mm, adapting to the printing needs of different types of materials (such as PLA, ABS, PETG, etc.).

[0029] Control System Module: This module connects to sensors and calculates the nozzle clogging probability in real time based on sensor data. Combined with multi-dimensional data such as ambient temperature and printing material characteristics, it dynamically adjusts the cleaning cycle and airflow intensity. The control program determines whether nozzle cleaning is necessary. When a clogging risk is detected, the system pauses printing, performs a cleaning operation, and resumes printing after cleaning is complete. The control system module can adaptively adjust the cleaning program's execution method based on parameters such as temperature, pressure, humidity, and particle size provided by the intelligent sensor module. This includes adjusting the intensity of the high-pressure airflow and the heating temperature, and dynamically optimizing the cleaning duration to adapt to the cleaning needs of different materials and degrees of clogging.

[0030] Material anti-clogging design: By optimizing the material feed path, the residence time of material at high temperatures is reduced, further lowering the probability of clogging. The specially designed nozzle inner wall uses high-temperature resistant material to reduce material adhesion. Simultaneously, a material property monitoring sensor is installed to monitor key parameters such as material humidity and particle size in real time. Combined with environmental parameters (such as the humidity around the printer), the system dynamically adjusts printing parameters. When the material humidity exceeds a preset threshold, the system automatically adjusts the nozzle heating temperature to reduce material cooling and retention, further reducing the risk of clogging.

[0031] How to use:

[0032] (1) Real-time monitoring: During the printing process, the system continuously acquires nozzle temperature and material flow data from sensors. The system analyzes this data in real time to determine whether there is a risk of nozzle clogging.

[0033] (2) Automatic Cleanup When the system detects a potential risk of congestion, it automatically pauses the current print job and starts a cleanup process. The cleanup process includes the following steps:

[0034] a. Heating: The heating system heats the nozzle to soften and remove residual material adhering to the inner wall of the nozzle.

[0035] b. Air jet: High-pressure airflow is injected into the nozzle to help blow away loose residue.

[0036] c. Vibration: The vibration device will slightly vibrate the nozzle to further assist the cleaning process and ensure that residual material is completely removed.

[0037] (3) After the recalibration and resumption of the print cleaning process is completed, the system will automatically recalibrate the nozzles to ensure that they are operating in the best condition. Then, the system will resume the print job and continue the printing process to ensure that the print quality is not affected.

[0038] (4) User Operation and Monitoring: Users can view the cleaning status and nozzle health through the control panel or software interface. In some cases, users can also manually start the cleaning program or adjust the cleaning parameters to meet specific printing needs.

Claims

1. A nozzle automatic cleaning and anti-clogging device for a 3D printer, characterized in that, The nozzle cleaning module, the intelligent sensing module and the control system module are connected; the nozzle cleaning module includes a high-pressure airflow system and a controllable heating system, which automatically adjusts the airflow intensity and heating temperature according to different material types and environmental conditions to effectively remove the residual materials and solidified substances in the nozzle; The intelligent sensing module is used for detecting the temperature, pressure, material flow condition and material characteristics of the nozzle; when detecting the risk of blockage, the intelligent sensing module transmits a signal to the control system module, and the control system module then starts the nozzle cleaning module to perform a cleaning operation and dynamically adjusts the cleaning program to ensure the optimization of the cleaning effect and the printing quality; The intelligent sensing module monitors the nozzle temperature and material flow state, the high-pressure airflow system is used for cleaning the residual materials in the nozzle through airflow, and the heating system is used for eliminating the solidified materials by adjusting the temperature; The intelligent sensing module further includes a temperature sensor, a pressure sensor, a material humidity sensor and a particle monitoring sensor, which are used for monitoring the temperature, pressure change and material characteristics of the nozzle in real time to determine whether the nozzle has the risk of blockage; The material humidity sensor monitors the humidity of the feed material with an accuracy of ±1% to ensure that the material humidity is kept within a set range, so as to prevent the nozzle from being blocked due to the enhanced adhesion caused by the moisture of the material; the particle monitoring sensor is used for detecting the particle size of the material to ensure that the material particles entering the nozzle are uniformly distributed, and the particle size monitoring accuracy can reach ±0.01 millimeter, which is suitable for the printing requirements of different types of materials.

2. A nozzle automatic cleaning and anti-clogging device for a 3D printer according to claim 1, characterized in that, The response time of the temperature sensor is 0.1 seconds, and the monitoring accuracy can reach ±0.5℃, which is suitable for different printing materials with a nozzle temperature range of 180℃ to 450℃.

3. A nozzle automatic cleaning and anti-clogging method for a 3D printer, characterized in that The nozzle automatic cleaning and anti-blocking device for the 3D printer includes the following steps: (1) monitoring the temperature, pressure, material flow state and material characteristics in the nozzle, the material characteristics including humidity and particle size; (2) when the intelligent sensing module detects the risk of blockage, the printing is automatically paused and the cleaning program is started; (3) according to the detected blockage degree, the high-pressure airflow intensity and the heating system temperature in the nozzle cleaning module are adjusted to clean the residual materials and solidified substances in the nozzle; (4) after the cleaning is completed, the nozzle calibration program is automatically executed to ensure that the nozzle state is normal, and then the printing process is resumed to ensure the printing quality.

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