Additive Manufacturing Nozzle Supplemental Heater Thermal Bonding

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Solution Overview

Problem

In additive manufacturing, maintaining high temperatures around deposited filaments is crucial for improving mechanical and thermal properties of printed parts, but existing methods face practical limitations such as fixed thermal conductivity of filaments and undesirable material changes at high nozzle temperatures.

Innovation Solution

Implementing pre-heating and post-heating configurations using supplemental heaters positioned laterally in front of and behind the nozzle, respectively, to extend the duration that deposited material remains at elevated temperatures, enhancing heat transfer and filament-to-filament bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the nozzle temperature is increased to maintain high temperature around deposited filaments, then the temperature of deposited layers is improved, but undesirable changes in material properties occur at high temperature

Engineering Contradiction:

Improvetemperature of deposited layersVSAvoidmaterial property stability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

A supplemental heater is introduced as an intermediary heating source positioned near the build chamber. This mediator provides additional thermal energy to the deposited layers without requiring the nozzle to operate at excessively high temperatures, thus maintaining material property stability while achieving the desired temperature in deposited layers

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heating function is segmented into two independent sources: the nozzle heater for melting and extruding the filament, and the supplemental heater for maintaining temperature in the build chamber and deposited layers. This segmentation allows each heater to operate within optimal temperature ranges, preventing material degradation

Inventive Principle:

Principle #1Segmentation

2Temperature

If the print speed is reduced to allow longer heating time, then the temperature maintenance is improved, but the productivity decreases

Engineering Contradiction:

Improvetemperature maintenance durationVSAvoidprinting speed

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The supplemental heater provides continuous thermal energy to the build chamber and deposited layers throughout the printing process. This continuous heating action ensures that temperature is maintained without requiring pauses or slow print speeds, allowing high productivity while achieving temperature maintenance

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The supplemental heater pre-heats the build chamber and previously deposited layers before new filaments are deposited. This preliminary heating action ensures that the thermal environment is already optimized for bonding when new material arrives, eliminating the need for slow print speeds

Inventive Principle:

Principle #10Preliminary action

3Temperature

If the build chamber temperature is increased to improve heat transfer, then the temperature distribution is improved, but energy consumption increases

Engineering Contradiction:

Improvebuild chamber temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The supplemental heater is positioned to provide localized heating to the build chamber and deposited layers where thermal energy is most needed. This local quality approach concentrates thermal energy in critical zones rather than uniformly heating the entire chamber, improving heat transfer efficiency while reducing overall energy consumption

Inventive Principle:

Principle #3Local quality

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 pre-heating and post-heating configurations significantly increase the temperature of deposited layers, leading to improved filament-to-filament neck growth and overall structural integrity of printed parts, with a passive and cost-effective approach that builds upon existing heating mechanisms.

Implementation Method 1

A supplemental heater is positioned laterally in front of and/or behind the dispensing nozzle to pre-heat and/or post-heat layers of material deposited by the dispensing nozzle

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

heat transfer directly from the hot nozzle

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

heat transfer during the filament deposition process plays a key role in determining overall properties of the part

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11602895B2Systems and methods for heating layers of material deposited using additive manufacturing

Publication Date: 2023.03.14 BOARD OF RGT THE UNIV OF TEXAS SYST

AI summary

In one embodiment, an additive manufacturing system includes a dispensing nozzle configured to dispense material to be used to manufacture a component, a barrel to which the nozzle is mounted, the barrel being configured to deliver the material to the dispensing nozzle, a barrel heater that surrounds the barrel, the barrel heater including a heating element configured to heat the barrel heater, the nozzle, and the material contained within the nozzle before it is dispensed from the nozzle, and a supplemental heater configured to heat previously deposited material so as to increase bonding and merging of the material that is being dispensed with the previously deposited material.