3D Printed Faucet with Interwoven Channels
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Solution Overview
Problem
Conventional faucet fabrication techniques are limited in constructing complex geometries, such as multiple undercuts, internal openings, and small diameter channels, which restrict the aesthetic and functional possibilities of plumbing products.
Innovation Solution
The use of 3-dimensional printing techniques, including metallic and multimedia 3-D printing, allows for the creation of complex geometries like interwoven net-like patterns and lattice structures in faucet components, enabling the production of structurally sound and aesthetically pleasing designs with multiple channels that diverge and converge, using materials like stainless steel, INCONEL, and plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional fabrication techniques are used, then manufacturing simplicity is maintained, but geometric complexity is limited
Solution Approach 1:
The patent replaces conventional mechanical fabrication methods (casting, molding, machining) with additive manufacturing technology. This substitution enables the creation of complex geometries including multiple undercuts, internal openings, and small diameter channels that are impossible to achieve with traditional mechanical processes, while maintaining manufacturing feasibility through automated 3D printing operations
Solution Approach 2:
The patent fundamentally changes the manufacturing parameters by transitioning from subtractive or form-based fabrication to additive layer-by-layer construction. This parameter change allows for the creation of complex water channels with specific geometric patterns (diverging and converging channels, lattice structures) that define both aesthetic appearance and functional water flow characteristics
2Adaptability or versatility
If complex geometries with multiple undercuts and internal openings are created, then aesthetic and functional possibilities are expanded, but manufacturing feasibility is reduced
Solution Approach 1:
Additive manufacturing replaces traditional mechanical fabrication systems, enabling the production of complex geometries with multiple undercuts and internal openings that would be impossible to create with conventional tools. The digital modeling and layer-by-layer construction process allows for unrestricted design freedom while maintaining manufacturing feasibility
Solution Approach 2:
The complex faucet geometry is segmented into multiple water channels that can be independently designed and manufactured. The channels are created as separate extruded features within the additive manufacturing process, allowing each channel to have complex cross-sections and pathways while being fabricated through standardized additive manufacturing operations
3Reliability
If multiple small diameter channels are fabricated, then functional performance is improved, but manufacturing capability is limited
Solution Approach 1:
Additive manufacturing replaces conventional machining and forming processes, enabling the fabrication of multiple small diameter channels with precise dimensional control. The layer-by-layer construction allows for the creation of channels with diameters too small to be machined while maintaining structural integrity and functional performance
Solution Approach 2:
The manufacturing approach changes from macro-scale forming to micro-scale additive construction. This parameter change enables the creation of multiple small diameter channels with precise control over channel size, shape, and position, achieving both functional performance requirements and manufacturing capability
Data Source
AI summary
Novel plumbing products, including faucets, are fabricated, e.g., using metallic 3-dimensional or other 3-D printing techniques, to have complex geometries, such as multiple channels that may diverge and re-converge near the spout. The geometries of the various channels can resemble interwoven net-like patterns that define various shapes between the channels. The plumbing fixtures may be formed from one or more of stainless steels, INCONEL, brass, bronze, polycarbonate, PVC, acrylics, rigid polyolefins, PET, carbon fiber, AES, or other plumbing fitting suitable corrosion resistant materials. In some embodiments, the handles of an exemplary faucet can include the same or a similar multiple channel configuration as the spout, providing an advantageously, aesthetically pleasing faucet system. In exemplary embodiments, faucet spouts and their handles are formed so as to couple to standard faucet underbodies, standard valve platforms, or standard threaded hose/waterway connections.