Additive Manufacturing Fluid Management for Nozzle Clog Prevention
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Solution Overview
Problem
Existing additive manufacturing apparatuses face challenges in improving manufacturing throughput for commercial production, particularly due to issues with clogged nozzles in print heads caused by contaminants such as excess build material and binder material, which affect the efficiency and performance of the printing process.
Innovation Solution
A fluid management system is introduced that includes a cleaning fluid path with a reservoir, pump, and drain, and a binder fluid path with a reservoir, pump, and purge bins, along with filters and controllers to manage and recirculate cleaning and binder fluids, ensuring effective cleaning and prevention of nozzle clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing apparatuses are scaled for commercial production, then productivity increases, but nozzle clogging from contaminants worsens
Solution Approach 1:
The system performs preliminary cleaning actions by equipping the print head with multiple nozzles positioned at different heights. Higher nozzles prevent contaminant accumulation before it reaches lower nozzles, proactively maintaining nozzle functionality throughout the printing process rather than reacting to clogs after they occur.
Solution Approach 2:
Elevated nozzles act as intermediary elements between the binder supply and the build platform. These intermediate nozzles intercept and prevent contaminant accumulation, serving as a protective barrier that maintains the reliability of the entire printing system while enabling continuous high-productivity operation.
2Reliability
If cleaning systems are added to remove contaminants, then nozzle reliability improves, but device complexity increases
Solution Approach 1:
The print head structure serves multiple functions simultaneously: it delivers binder material through nozzles and prevents contaminant accumulation through elevated nozzle positioning. This multi-functional design integrates the cleaning/prevention function directly into the existing print head rather than adding separate cleaning mechanisms, thereby improving reliability without significantly increasing device complexity.
Solution Approach 2:
The elevated nozzle configuration enables the print head to self-clean by preventing contaminant accumulation in the first place. The design inherently resists clogging through its geometric arrangement, eliminating the need for external cleaning systems or complex maintenance mechanisms while maintaining consistent nozzle functionality.
3Reliability
If multiple nozzles at different heights are used, then contaminant prevention improves, but manufacturing precision requirements increase
Solution Approach 1:
The invention changes the vertical positioning parameter of nozzles, arranging them at different heights along the Z-axis. This parameter modification creates a gradient structure where higher nozzles prevent contaminant buildup, improving reliability without requiring extreme precision since the height differences are macroscopic rather than microscopic.
Solution Approach 2:
Different nozzles are positioned at different local heights to serve different functions in contaminant prevention. This local differentiation creates zones of protection where higher nozzles handle contaminant interception while lower nozzles perform standard printing, allowing the system to achieve reliability improvements with moderate overall precision requirements.
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 enhances the throughput of additive manufacturing by reducing nozzle clogging, maintaining print head efficacy, and optimizing the additive manufacturing process by allowing simultaneous or overlapping steps, thereby reducing overall cycle time.
Implementation Method 1
a pump configured to deliver the cleaning fluid from the at least one cleaning fluid reservoir to at least one cleaning station vessel
Implementation Method 2
a pump configured to deliver the binder fluid from the at least one binder reservoir through an ink supply system to a print head manifold
Implementation Method 3
the cleaning fluid path further comprises a filter positioned between the at least one cleaning fluid reservoir and the pump
Implementation Method 4
the binder fluid path further comprises a filter positioned between the binder purge bin and the at least one binder reservoir
Implementation Method 5
the cleaning fluid path further comprises a heater to heat the cleaning fluid
Data Source
AI summary
Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.