Aligned Pellet Feeding for Faster 3D Printing Extrusion
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Solution Overview
Problem
The existing 3D printing methods using pelleted materials face challenges with long start-up and steady-state extrusion times due to pressure buildup in extruder screws, which slows down the printing process.
Innovation Solution
The method employs elongated pellets aligned using counter-rotating wheels instead of an extruder screw, allowing for faster start-up and steady-state extrusion by eliminating pressure release times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an extruder screw is used to transport pelleted 3D printable material, then the material can be fed into the printer head, but pressure builds up in the interior of the extruder screw causing long start-up and steady-state extrusion times
Solution Approach 1:
The patent removes the extruder screw component from the system entirely. Instead of using a screw mechanism to transport and extrude the pelleted material, the invention uses a direct feeding system where pellets are supplied to the printer head through a hopper and guided by gravity and vibration, eliminating the pressure buildup issue inherent in screw-based extrusion systems.
Solution Approach 2:
The patent replaces the mechanical screw extrusion system with a gravity-based feeding system assisted by vibration. The pellets fall through a hopper under gravity, and vibration mechanisms prevent clogging, eliminating the need for mechanical pressure application and release cycles that characterize traditional screw extruders.
2Productivity
If traditional extrusion process with extruder screw is used, then pelleted material can be processed, but the printing process is slowed down due to pressure buildup and release cycles
Solution Approach 1:
The patent enables continuous material supply to the printer head by using a hopper system where pellets are constantly fed under gravity. The vibration mechanism ensures continuous flow without interruptions or pressure cycles, allowing the printing process to maintain steady state operation without periodic start-up and steady-state transitions.
3Ease of manufacture
If granulated 3D printable material is used instead of filament, then cost efficiency is improved and material versatility is enhanced, but start-up and steady-state extrusion times increase
Solution Approach 1:
The patent changes the physical parameters of the material feed system by using elongated pellets with specific aspect ratios (length to diameter ratio between 2:1 and 10:1) instead of traditional spherical or irregular granules. This geometric parameter change, combined with vibration assistance, enables efficient feeding of cost-effective pelleted materials at high speeds without the drawbacks of traditional extrusion.
Data Source
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AI summary
The present invention relates to a method for producing a 3D item (509) by means of fused deposition modelling using a 3D printer (500), the method comprising the steps of: a) providing a plurality of elongated pellets (503), each elongated pellet of the plurality of elongated pellets (503) comprising a first 3D printable material comprising a first thermoplastic polymer, wherein each elongated pellet of the plurality of elongated pellets (503) has a length L along a longitudinal axis and a width W in a direction being substantially perpendicular to the longitudinal axis, b) feeding the plurality of elongated pellets (503) into a feeding container (501). c) aligning the plurality of elongated pellets (500) in an aligning element (505), such that the longitudinal axes of elongated pellets of the plurality of elongated pellets (503) are substantially parallel to each other, thus forming an aligned plurality of elongated pellets. d) feeding the aligned plurality of elongated pellets (503) through a feeding duct (506) into a printer head of the 3D printer (500); and e) layer-wise depositing the first 3D printable material thus obtaining the 3D item (509) comprising at least one layer of first 3D printed material.