3D Printing Nozzle Angle Control for Uniform Layer Thickness
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Solution Overview
Problem
Additive manufacturing apparatuses face shape errors due to nozzle orientation changes, leading to inconsistent layer thickness and shape inaccuracies in three-dimensional object formation.
Innovation Solution
The apparatus adjusts the layer forming conditions, such as nozzle movement speed, material ejection amount, and laser output, based on the inclination angle of the nozzle to maintain a consistent layer thickness and improve shape accuracy by dynamically changing the layer forming conditions in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the nozzle orientation is changed to manufacture objects with various shapes, then the versatility of the additive manufacturing apparatus is improved, but the layer thickness consistency deteriorates
Solution Approach 1:
The patent applies dynamics by making the layer forming conditions variable rather than fixed. The control unit dynamically adjusts nozzle movement speed, material ejection amount, and laser output based on the instantaneous inclination angle of the nozzle. This dynamic adaptation allows the system to maintain consistent layer thickness despite changes in nozzle orientation, resolving the contradiction between versatility and manufacturing precision.
Solution Approach 2:
The patent changes physical parameters (nozzle movement speed, material ejection amount, laser output) in response to changing nozzle inclination angles. By modifying these parameters dynamically, the system compensates for the effect of orientation changes on layer thickness, enabling both shape versatility and thickness consistency to be achieved simultaneously.
2Adaptability or versatility
If the nozzle inclination angle increases to create overhanging deposits, then the ability to manufacture complex geometries is improved, but the layer thickness control precision deteriorates
Solution Approach 1:
The patent implements feedback control by continuously monitoring the inclination angle of the nozzle and using this information to adjust layer forming conditions. The control unit receives inclination angle data and automatically modifies nozzle movement speed, material ejection amount, and laser output to compensate for thickness variations, maintaining precision even when creating overhanging structures.
Solution Approach 2:
The system performs preliminary adjustment of layer forming conditions based on predicted inclination changes. By proactively modifying parameters before the actual deposition occurs, the system prepares the optimal conditions for maintaining layer thickness consistency during complex geometry fabrication.
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
This approach ensures the formation of layers with uniform thickness and reduces shape errors, resulting in objects with shapes closer to the desired design, even when the nozzle orientation changes significantly.
Implementation Method 1
supply powdery material and output laser light from a nozzle to solidify the material
Implementation Method 2
output laser light from a nozzle to solidify the material, and form layers of the solidified material
Data Source
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AI summary
An additive manufacturing apparatus (1) according to one embodiment includes a support surface (11a), a manufacturing unit (12), and a control unit (14). The support surface (11a) can support an object (3) that is additively manufactured. The manufacturing unit (12) includes a nozzle (21) that moves relative to the support surface (11a), ejects powder (M), and outputs an energy ray (L) to melt or sinter the powder (M), thereby forming a layer (3b) of the object (3). The manufacturing unit (12) can change the orientation of the nozzle (21). The control unit (14) can change a layer forming condition for the nozzle (21) in accordance with a change in the orientation of the nozzle (21).