Additive Manufacturing System With Articulation And Multi-Nozzle Extrusion
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Solution Overview
Problem
Existing manufacturing processes for components like footwear are laborious and time-consuming, involving the adherence of various materials.
Innovation Solution
An additive manufacturing system with an articulation system that includes an actuator assembly, a base, an arm, and an end-piece defining a shoe last, along with a print system that extrudes additive material through nozzles with multiple orifices, controlled by a computing system to determine end-piece paths and control the additive process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used to form components like footwear, then various materials can be adhered or attached to one another, but the process becomes laborious and time-consuming
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process. The articulation system with multiple nozzles can extrude different materials simultaneously in one operation, eliminating the need for separate processes to attach various materials together. This merging of operations directly reduces manufacturing time and improves productivity.
Solution Approach 2:
The system changes the fundamental parameter of material application from sequential layer-by-layer or component-by-component assembly to simultaneous multi-material extrusion. By controlling multiple nozzles to extrude different filaments at the same time, the process transforms from a time-consuming assembly process to an efficient single-step manufacturing process.
2Productivity
If an articulation system with multiple nozzles is used to extrude multiple filaments simultaneously, then manufacturing efficiency improves, but device complexity increases
Solution Approach 1:
The articulation system is designed as a multi-functional platform that can perform various manufacturing tasks through its array of nozzles. Each nozzle can be configured to extrude different materials, and the system can adapt to different article designs by programming the articulation movements. This universality allows a single system to handle diverse manufacturing requirements, justifying the increased complexity through versatile capability.
Solution Approach 2:
The system uses digital modeling and computational control to manage complexity. Instead of physically complex mechanical linkages for each function, the patent employs software-controlled articulation movements and nozzle positioning. The digital twin approach allows complex geometries and multi-material arrangements to be created through programming rather than complex mechanical design.
3Speed
If multiple filaments are extruded simultaneously through a nozzle, then manufacturing speed increases, but control precision requirements increase
Solution Approach 1:
The system incorporates sensors and control mechanisms that provide real-time feedback on filament extrusion and positioning. The articulation system monitors the position and status of each nozzle and adjusts its movements accordingly to maintain precise control. This feedback loop enables high-speed multi-filament extrusion while ensuring accurate placement and consistent material properties.
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
The system enables efficient and precise manufacturing of complex components by extruding multiple filaments simultaneously, allowing for the creation of customized products with varied characteristics, such as density and compression levels.
Implementation Method 1
a print system configured to extrude an additive material towards the end-piece. The print system may include a first nozzle having a plurality of orifices
Implementation Method 2
The print system may further include a blower configured to blow the additive material toward a defined location
Implementation Method 3
a compressor unit positioned within a working envelope of the articulation system. The compressor unit may be configured to alter a characteristic of the article based on contact between the compressor unit and the article
Data Source
AI summary
An additive manufacturing system is described herein that includes an articulation system. The articulation system may include an actuator assembly, a base operably coupled with the actuator assembly, and an arm rotatable relative to the base. An end-piece may be operably coupled with a distal end portion of the arm. The end-piece may be rotatable relative to the arm. A print system may be configured to extrude an additive material towards the end-piece. A computing system may be configured to receive an input related to a defined design of an article, determine an end-piece path through actuation of the articulation system based on the defined design, and control the print system and the articulation system to extrude the additive material from the print system during the first additive process, wherein the first additive process comprises extruding multiple filaments of additive material simultaneously through the first nozzle.