3D Print Material Hopper Segmentation for Dynamic Composition
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Solution Overview
Problem
Existing 3D printing technologies are inefficient and costly due to the limited ability to dynamically mix and utilize different proportions of unused and recycled build materials during a single print operation, restricting the formation of complex structures and wasting materials.
Innovation Solution
A system with multiple hoppers for unused, recycled, and reclaimed build materials allows for on-the-fly mixing and delivery of varying proportions of these materials to the print zone, enabling the formation of complex 3D objects with different material compositions at different parts of the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If unused build material is combined with recycled build material in preparation for a next 3D print operation, then cost-effectiveness and material efficiency are improved, but the ability to dynamically adjust material composition during the print operation is limited
Solution Approach 1:
The system divides the build material supply into multiple separate hoppers, each containing different proportions of unused and recycled build materials. This segmentation allows the system to select and deliver specific material compositions from different hoppers during the print operation, rather than using a single pre-mixed composition for the entire operation.
Solution Approach 2:
The system enables dynamic adjustment of material composition by switching between different hoppers containing different material mixtures during the print operation. The controller can change which hopper supplies material to the print zone based on the current printing requirements, allowing real-time adaptation of material properties without stopping the operation.
2Device complexity
If a single mixture of build materials is prepared in advance, then material delivery is simplified, but the ability to form complex structures with varying material properties is restricted
Solution Approach 1:
The build material supply system is segmented into multiple independent hoppers, each containing a different pre-prepared mixture of unused and recycled materials. This allows the system to maintain relatively simple individual hopper designs while achieving complex overall material delivery capabilities through the combination of multiple hoppers.
Solution Approach 2:
Different regions or layers of the printed object can be formed using different material compositions by selecting appropriate hoppers for different stages of the print operation. This enables local optimization of material properties for different parts of the object, such as using higher recycled content for non-critical regions and higher unused content for critical regions.
3Reliability
If only unused build material is used for the entire print operation, then material quality and print reliability are improved, but material cost increases
Solution Approach 1:
The system changes the composition parameter of the build material by utilizing multiple hoppers with different ratios of unused to recycled materials. The controller can select hoppers with higher unused material content for critical printing stages to maintain reliability, while using hoppers with higher recycled content for less critical stages to reduce costs.
Solution Approach 2:
The system creates composite material supply by combining unused and recycled build materials in different proportions across multiple hoppers. This allows the formation of composite structures where different regions of the printed object use different material compositions, optimizing both cost and performance.
Data Source
AI summary
Example implementations relate to different mixtures of build materials deliverable during a three dimensional (3D) print operation. In some examples, a 3D print apparatus may include a delivery hopper to deliver build material to a print zone of the 3D print apparatus and a plurality of build material hoppers to which the delivery hopper is connected for receipt of at least one of a corresponding plurality of build materials. A controller of the 3D print apparatus may direct that variable proportions of a first build material relative to a second build material are receivable by the delivery hopper from the plurality of build material hoppers during the 3D print operation, where different mixtures of the variable proportions of the first build material and the second build material are deliverable to the delivery hopper during the 3D print operation.