3D Printing Nozzle Continuous Discharge for Interlocking Layer Strength
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Solution Overview
Problem
Existing three-dimensional forming methods, such as those using ink jet technology, face issues with reduced strength in the stacking direction due to weakened adhesive forces between deposited layers, leading to potential separation of stacked materials.
Innovation Solution
A manufacturing method involving continuous discharge of forming material from a nozzle while moving it in perpendicular and parallel directions to a forming table, utilizing a control unit and a flat screw mechanism to generate and deposit the material, enhancing the strength of the formed object by forming columnar and linear parts that interlock effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If material is deposited by stacking layers in a predetermined stacking direction, then three-dimensional formed object is formed, but the overall strength in the stacking direction is reduced due to layers separating from each other
Solution Approach 1:
The continuous material deposition is segmented into discrete droplets that are deposited layer by layer. Each droplet forms a distinct segment that bonds with adjacent segments, creating a segmented structure that maintains strength while enabling layer-by-layer formation. The segmentation allows for controlled deposition and bonding interfaces between layers.
Solution Approach 2:
The invention transitions from purely vertical layer stacking to a multi-dimensional deposition approach where material is deposited in both vertical and horizontal directions. By adding horizontal displacement of the nozzle, the structure gains lateral interlocking features that prevent layer separation and enhance overall strength in the stacking direction.
2Productivity
If droplets are deposited one at a time with solvent evaporation, then three-dimensional object is formed, but adhesive force between previously dripped ink and subsequently dripped ink is weakened
Solution Approach 1:
The material is discharged continuously from the nozzle rather than in discrete interrupted droplets. This continuous discharge maintains a consistent material flow that ensures proper bonding between deposited portions, eliminating the adhesive force reduction caused by intermittent deposition and solvent evaporation cycles.
Solution Approach 2:
The invention changes the discharge parameters from intermittent droplet ejection to continuous material flow. By adjusting the discharge conditions to maintain continuous flow while controlling the deposition rate, the material achieves optimal bonding strength without compromising forming productivity. The continuous discharge parameter ensures consistent adhesive properties throughout the deposition process.
Data Source
AI summary
In a manufacturing method of a three-dimensional formed object, the method includes a first discharging in which a forming material is continuously discharged from a nozzle while causing a position of the nozzle to change with respect to the forming table in a first direction which is perpendicular to a top surface of the forming table to cause the forming material to be deposited in the first direction, a second discharging in which the forming material is continuously discharged from the nozzle while changing the position of the nozzle with respect to the forming table in a second direction which is parallel to the top surface of the forming table to dispose the forming material along the second direction, and repeating in which the first discharging and the second discharging are repeated.