Additive Manufacturing Nozzle with Integrated Heater and Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current fused filament fabrication (FFF) and fused granulate fabrication (FGF) systems face limitations in creating strong non-planar structures due to strength constraints and slow printing speeds, particularly when operating in confined spaces or at angles greater than 22.5°, as existing nozzles and heating systems are bulky and interfere with extrusion angles.
Innovation Solution
A nozzle design featuring a thermally conductive body with integrated heater and temperature sensor conduits, allowing for precise temperature control and extrusion, which tapers to a nozzle opening, enabling efficient extrusion of material at various angles without a separate heating block, thus enhancing structural strength and printing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If insulation is added to maintain nozzle temperature, then temperature control is improved, but nozzle size increases and ability to operate in confined spaces is reduced
Solution Approach 1:
The heating element and temperature sensor are integrated directly into the nozzle body, combining the heating function, sensing function, and nozzle function into a single integrated component. This eliminates the need for separate insulation layers and external heating blocks, maintaining temperature control capability while reducing overall nozzle size and enabling operation in confined spaces.
Solution Approach 2:
The heating element and temperature sensor are extracted from separate components and embedded directly within the nozzle body structure. This integration removes the need for additional insulation layers that would increase nozzle diameter, allowing the nozzle to fit in confined spaces while maintaining precise temperature control through the embedded sensors and heaters.
2Productivity
If larger material input pellets are used to improve extrusion speed, then printing speed is improved, but heating and extrusion system becomes bulky and print angles are limited
Solution Approach 1:
The heating system is designed with localized heating zones concentrated at the nozzle tip and material input region, rather than requiring a large distributed heating system. This allows efficient melting and extrusion of larger pellets while keeping the heating system compact, enabling both high extrusion speed and access to confined spaces with complex print angles.
3Temperature
If heat block is used with commercial nozzles, then temperature control is improved, but extrusion angles near or above 22.5° are interfered with and arm dexterity is limited
Solution Approach 1:
The heating element and temperature sensor are merged directly into the nozzle body, eliminating the separate heat block component. This integration removes the physical obstruction that limited extrusion angles to below 22.5°, allowing the robotic arm to access confined spaces and print at steeper angles while maintaining precise temperature control through the embedded sensing and heating elements.
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 nozzle design improves the strength and speed of additive manufacturing by maintaining material above the glass transition temperature throughout the extrusion process, allowing for the creation of stronger structures and enabling printing at angles up to 45° without interference, while reducing bulkiness and increasing operational flexibility in confined spaces.
Implementation Method 1
heating, by the heater, the nozzle to a temperature above a glass transition temperature of the material
Implementation Method 2
a body having a thermally conductive material
Implementation Method 3
a sensor conduit, adjacent to the first conduit, extends from a sensor opening in the top end and into body towards the extrusion end
Implementation Method 4
extruding extrudate from the nozzle opening wherein the extrudate is in a liquid state upon exiting the nozzle opening
Data Source
AI summary
A nozzle for additive manufacturing having a body having a thermally conductive material, a front side opposite a back side, a first side opposite a second side, the first side and the second side connected to and between the front side and the back side. The nozzle further has a top end opposite an extrusion end, and the body tapers at the extrusion end to a nozzle opening. A first conduit extends through the body from an opening in the top end to the nozzle opening in the extrusion end. A heater conduit, adjacent to the first conduit, extends from a heater opening in the top end and into the body towards the extrusion end and a sensor conduit, adjacent to the first conduit, extends from a sensor opening in the top end and into body towards the extrusion end.