3D Printer Print Head Automatic Clearing via Reverse Flow

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Solution Overview

Problem

Existing three-dimensional printing methods face defects due to material feed disruptions caused by contamination and wear in the print head, requiring manual or semi-automatic intervention for clearing, which can affect print quality and lead to prolonged downtime.

Innovation Solution

A method using an additional drive system to reverse and then gradually increase the material feed speed, disengaging measurement systems initially to clear the print head without user intervention, employing both primary and auxiliary drive systems to create negative pressure and push out dirt, allowing for automated cleaning and resumption of the printing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual or semi-automatic clearing methods are used, then user intervention can remove the problem, but print quality may be affected and downtime is prolonged

Engineering Contradiction:

Improveprint qualityVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs automatic clearing of the print head without user intervention. The control unit automatically detects extrusion errors, activates the auxiliary drive system to reverse material flow, and resumes printing once clearing is complete, enabling the system to service itself and eliminate the need for manual intervention

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The clearing process is integrated into the printing workflow without requiring interruption of the overall printing operation. The system detects errors, performs clearing, and resumes printing in a continuous automated sequence, minimizing downtime and maintaining productivity

Inventive Principle:

Principle #20Continuity of useful action

2Measurement precision

If measurement systems remain active during clearing, then extrusion monitoring is continuous, but clearing effectiveness is reduced due to measurement interference

Engineering Contradiction:

Improveextrusion monitoring accuracyVSAvoidclearing process effectiveness

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The measurement system is periodically activated and deactivated based on the clearing state. During active clearing, the measurement system is deactivated to avoid interference with the reverse flow process. After clearing completes and forward flow resumes, the measurement system is reactivated to continue monitoring extrusion quality

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The control unit preemptively deactivates the measurement system before initiating the clearing process to prevent measurement interference. This preliminary action ensures that the clearing operation can proceed without disruption from measurement system activity

Inventive Principle:

Principle #10Preliminary action

3Productivity

If material feed speed is increased abruptly after clearing, then printing productivity is restored quickly, but extrusion quality may be compromised

Engineering Contradiction:

Improveprinting speedVSAvoidextrusion quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The material feed speed is dynamically adjusted during the clearing process. The auxiliary drive system gradually increases the feed rate from zero to the target speed rather than abruptly changing it, allowing the extrusion system to adapt smoothly and maintain quality while restoring productivity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The feed speed parameter is changed incrementally during clearing. The system transitions from reverse flow at zero forward speed to forward flow, gradually increasing the speed parameter to the rated value, ensuring extrusion quality is maintained during the transition

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables automated clearing of print heads with minimal downtime, maintaining extrusion quality by removing blockages and contaminants without user intervention, ensuring continuous printing operation.

Implementation Method 1

an additional drive system for material feed is being actuated causing the printing material to flow firstly in the reverse direction and then in the forward direction... employing both primary and auxiliary drive systems to create negative pressure and push out dirt

Methodology Applied

Scientific EffectNegative pressure: Pressure Gradient

Data Source

PatentEP3613558B1Method for automatic clearing print head of three-dimensional printing device

Publication Date: 2022.07.20 3D GENCE SP ZOO

Figure 1

AI summary

The present invention related to a method for automatic clearing a print head (2) of a three-dimensional printer, in which a measuring system (1) measures the amount of a printing material (5) fed per unit of time by a primary drive system (3) for feeding the printing material (5). In addition to the primary drive system (3), a secondary drive system (4) for feeding the printing material (5) is used, said drive system (4) is being actuated after detection of an error, wherein after material withdrawal, the printing material (5) is fed again with increasing speed from zero to a rated speed using both drive systems (3,4).