3D printing head with infinite rotating nozzle for additive manufacturing

Abstract

The proposed rotary print head combines printing speed and precision for applications requiring both rapid material deposition and high-resolution detail. It combines the advantages of a large nozzle for large volumes with those of a small nozzle for angles and complex areas. This technology enables the faster production of large parts while maintaining fine contours, particularly in high-temperature environments where precision is crucial. Compatible with standard or high-temperature 3D printers and pellet extruders, it adapts to a variety of materials and applications. Post-processing software or scripts optimize nozzle rotation management to improve movement efficiency during printing.

Description

Title of the invention: 3D printing head with infinite rotating nozzle for additive manufacturing. Field of the invention

[0001] This invention is in the field of additive manufacturing, more particularly in the field of 3D printers with fused deposition modeling technology and print heads equipped with rotating nozzles allowing precise control of material flow. Prior art

[0002] Several print head solutions for 3D printers have been proposed in the prior art. For example, US patent 2017 / 0320267 A1 describes a print head using polymer seals for nozzle sealing. However, the use of polymer materials for the seals has limitations in terms of heat resistance, which restricts the application of this technology in high-temperature environments. These seals can also deform under prolonged thermal stress, compromising the print head's sealing.

[0003] EP patent 3 117 982 B1 proposes a variable-size nozzle capable of adjusting the extrusion width during printing. While this approach offers interesting flexibility, it introduces additional mechanical complexity that makes its manufacture and integration into standard systems more expensive, cumbersome, and technically demanding.

[0004] Thus, despite these advances, there is still a need for a print head offering infinite nozzle rotation, with a reliable sealing mechanism in high-temperature environments and a simplified design, compatible with standard and high-temperature 3D printers. Technical problems to solve

[0005] The proposed print head must meet several key requirements for use in standard and high-temperature environments. In particular, it is essential that the head be compact and lightweight to minimize the load on the printer's motion system and avoid reducing printing accuracy and speed. Furthermore, the use of polymer seals is prohibited, as these do not adequately withstand the thermal stresses of high-temperature engineering materials. Sealing must be achieved through robust mechanical solutions, such as polished surfaces held under pressure, ensuring increased durability and reliability under high-temperature conditions.

[0006] The objective of the invention is to provide an infinite rotating print head that maintains a simple, lightweight and compact design, while offering compatibility with standard and high-temperature 3D printers, without compromising the high-temperature resistance of the extruded materials. Presentation of the invention

[0007] The present invention relates to a print head for a 3D printer equipped with an infinite rotating nozzle. This print head combines large volume material deposition while maintaining printing fineness to print details of the part. This print head makes it possible to significantly reduce printing times while maintaining the detail and fineness of the part to be printed. The nozzle rotation is driven by a stepper motor or other motor, allowing integration into most 3D printer controllers, whether standard or high-temperature models. The moving parts are sealed by the pressure of two polished surfaces held in place by a spring washer. Nozzle rotation is achieved via a gear system that relocates the motor to a cooler, upper section, suitable for high-temperature environments. This print head can be easily adapted to various extruders, including pellet extruders, and is compatible with standard software through G-code post-processing. Detailed description of the invention

[0008] The print head comprises:

[0009] Rotation motor: A stepper motor allowing infinite rotation of the nozzle. This motor is compatible with standard and high-temperature 3D printer controllers, ensuring broad compatibility.

[0010] Printing capacity: This printhead combines the advantages of conventional printheads by offering both: a. Fast printing, similar to that obtained with a head equipped with a large nozzle, which allows large volumes of material to be deposited in a short time. b. High print quality, comparable to that of a print head with a small nozzle, thanks to the controlled rotation of the nozzle and the precise adjustment of its movements, especially in corners and complex areas.

[0011] Sealing system: Effective sealing is achieved by the pressure of two polished surfaces, held under pressure by a spring washer or any other type of pressure spring. This mechanism provides durable sealing in both standard environments and high-temperature conditions.

[0012] Rotation system: Infinite rotation is made possible by a gear system which offsets the axis of rotation, moving the motor to a cooler area to prevent any thermal interference.

[0013] Rotary Nozzle: The rotary nozzle of the print head can adopt various shapes, such as a rounded rectangle, a rectangle, an oblong, or any other shape depending on the printing requirements. This nozzle is directly driven by the rotary gear, ensuring synchronization with the movement of the print head axis. Furthermore, the nozzle is easily interchangeable, allowing for quick and easy maintenance. It is inserted into the rotary gear and indexed, which guarantees precise positioning during replacement.

[0014] Adaptability: The print head is adaptable to various types of extruders, including pellet extruders. It is compatible with standard or high-temperature printers, thus offering great flexibility for the user.

[0015] Software: The print head operates with standard software, which may be open source or proprietary. This standard software generates the displacement calculations for prints using a large nozzle the size of the large length of the rotating nozzle.

[0016] After the initial generation of the path by this standard software, a script or complementary software is used to take these paths and add to them: a. Additional movements and nozzle axis rotations to optimize printing in all corners and angles of the basic path while maintaining fine printing in corners, thanks to a precise nozzle rotation control mechanism. b. A nozzle axis rotation for all linear movements, allowing precise control of nozzle orientation and optimization of printing performance, providing in all areas where possible a high printing flow rate, identical to that of the standard software with the large nozzle. c. The software complementation performs what is called in 3D printing jargon post-processing

[0017] The attached drawings illustrate the invention: Fig. 1 represents the entire device in perspective view in the case of use on a filament head. Figure [Fig.2] represents the lower part of the device in cross-section along the XZ plane in the case of use on a filament head. Fig. 3 represents the lower part of the device in cross-section along the XZ plane in the case of use on a pellet head with a screw extruder. Figure 4 represents the operating principles of the post-processing software: on the left a standard path generated by standard software, the right part represents the modifications in the paths made by the post-processing software. Description of the figures

[0018] [Fig. 1]: Perspective overview of the rotating 3D printing head Main Heating Body (1): Central part of the head which heats the material for extrusion. Rotary Nozzle (6): Nozzle that can take different shapes (rectangular, oblong, etc.) and is interchangeable. Maintenance Cover (7): Removable cover allowing easy access to internal components for maintenance. Coupling Allowing Thermal Expansion (9): Flexible coupling that compensates for dimensional variations due to temperature changes. Drive Tube (10): Tube transmitting the rotational movement of the motor to the nozzle via the gear and thermally insulating the nozzle rotation motor from the heating area. Cold Zone of the Head (13): Upper part of the head, thermally insulated. Maintenance Cover (14): Removable cover allowing easy access to internal components for maintenance. Nozzle Rotation Drive Motor (15): Stepper motor that drives the rotating nozzle, located in a cold zone to avoid the effects of heat. Upper Coupling Allowing Support for Thermal Expansion (16): Flexible coupling located in the upper part, allowing to compensate for thermal expansions due to temperature variations. Commercial Standard Filament Extruder (17): Classic filament extruder, compatible with the majority of 3D printers available on the market. Filament Feed Guide (18): Component that guides filament from the extruder to the print head to ensure a continuous flow of material.

[0019] [Fig.2]: Cross-sectional view of the rotating 3D printing head Main Heating Body (1): Central part of the head which heats the material for extrusion. Sealing zone (2): Zone where sealing is ensured by pressure between two polished surfaces, preventing leakage of material at high temperature. Nozzle Pivot Drive Gear (3): Gear that allows the nozzle to rotate to direct the extrusion. High Temperature Nozzle Guide Bearing (4): Bearing capable of withstanding high temperatures, ensuring precise guidance of the rotating nozzle. Spring Washer (5): Element which ensures the necessary pressure between the surfaces to maintain the seal. Rotary Nozzle (6): Nozzle which can take different shapes (rectangular, oblong, etc.) and which is interchangeable and indexed in the driven gear. Maintenance Cover (7): Removable cover allowing easy access to internal components for maintenance. Drive pinion (8): Pinion that transmits the movement from the motor to the nozzle rotation gear. Coupling Allowing Support for Thermal Expansion (9): Flexible coupling that compensates for misalignments due to dimensional variations caused by temperature changes. Drive Tube (10): Tube transmitting the rotational movement of the motor to the nozzle via the gear and thermally insulating the nozzle rotation motor from the heating area. Interchangeable Intermediate Spacer (11): Spacer that can be replaced as needed to adjust the position of components. Filament Entry Zone (12): Zone where the filament is introduced to be melted and extruded. Cold Zone of the Head (13): Upper part of the head, thermally insulated, where the motor and other heat-sensitive components are located to prevent overheating. Maintenance Cover (14): Removable cover allowing easy access to internal components for maintenance.

[0020] [Fig.3]: Device in cross-section along the XZ plane in the case of use on a pellet head with screw extruder. Main Heating Body (1): Central part of the head which heats the material for extrusion. Sealing zone (2): Zone where sealing is ensured by pressure between two polished surfaces, preventing leakage of material at high temperature. Nozzle Pivot Drive Gear (3): Gear that allows the nozzle to rotate to direct the extrusion. High Temperature Nozzle Guide Bearing (4): Bearing capable of withstanding high temperatures, ensuring precise guidance of the rotating nozzle. Spring Washer (5): Element which ensures the necessary pressure between the surfaces to maintain the seal. Rotary Nozzle (6): Nozzle which can take different shapes (rectangular, oblong, etc.) and which is interchangeable and indexed in the driven gear. Maintenance Cover (7): Removable cover allowing easy access to internal components for maintenance. Drive pinion (8): Pinion that transmits the movement from the motor to the nozzle rotation gear. Coupling Allowing Support for Thermal Expansion (9): Flexible coupling that compensates for misalignments due to dimensional variations caused by temperature changes. Drive Tube (10): Tube transmitting the rotational movement of the motor to the nozzle via the gear and thermally insulating the nozzle rotation motor from the heating area. Interchangeable Intermediate Spacer (11): Spacer that can be replaced as needed to adjust the position of components. Material Entry Zone (12): Zone where material granules are introduced after being melted and extruded. Maintenance Cover (14): Removable cover allowing easy access to internal components for maintenance. Extrusion Screw (19): Screw used to push material granules through the barrel, in order to melt and extrude them. Extrusion Sleeve (20): Heated cylinder containing the extrusion screw, in which the granules are melted and prepared for extrusion via the rotating nozzle.

[0021] [Fig.4]: Operating principles of the post-processing software Left side of the figure - original path: Large Diameter Nozzle Used to Calculate Origin Path (30): Large diameter nozzle used by the standard software to generate the initial path. Origin Path in Dotted Line (31): Origin trajectory generated by the standard software, represented in dotted line. Direction of Movement of the Origin Path (32): Direction of movement of the path generated by the standard software. Minimum Possible Radius with the Original Path (33): Minimum radius achievable with the large diameter nozzle during the initial path. Right side of the figure - Modifications made by the post-processing software: Shape of the Rotary Nozzle (34): Shape of the rotary nozzle used by the post-processing to optimize the path. Direction of Movement of the Path (35): Direction of movement after processing by the post-processing software. Paths Added by Post-processing Software (36): Additional paths added by the software to optimize the corners and angles of the original path. Minimum Possible Radius with Rotary Nozzle (37): New minimum radius achievable thanks to the shape of the rotary nozzle. At the Ends of the Added Paths, Nozzle Positioned According to the Median (38): The nozzle is oriented according to the median of the trajectories at the ends of the additional movements. Nozzle Positioned Perpendicular to the Direction of Travel (39): The nozzle is oriented perpendicular to the direction of travel to improve material flow.

Claims

Demands

1. 3D printer print head, characterized by an infinitely rotating nozzle(6), compatible with standard 3D printer controllers.

2. Print head according to claim 1, wherein the rotation of the nozzle (6) is controlled by a gear system (3)(8) offsetting the axis of rotation, allowing the motor (15) to be moved to a cooler area for use in standard or high-temperature 3D printers.

3. Print head according to any one of the preceding claims, wherein the sealing is ensured by the pressure of two polished surfaces(2), held by a spring system(5), allowing use in high temperature or standard environments.

4. Print head according to any one of the preceding claims, characterized by its ability to combine a high printing speed(30), while maintaining fine printing in the corners(37), thanks to a precise control mechanism of the nozzle rotation(3).

5. Print head according to any one of the preceding claims, wherein the software generating the path is standard(31), with post-processing of the GCode file to optimize movement in corners(36)(37) and angles of the model.

6. Print head according to any one of the preceding claims, adaptable to pellet(19)(20), filament(17) extruders and other types of extruders.

7. Print head according to any one of the preceding claims, characterized in that the rotating nozzle (6) has a shape selected from a set of configurations including a rectangular shape, a rounded rectangular shape, an oblong shape and an oval shape.

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