3D Shaping Device With Area-Based Nozzle Flushing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing three-dimensional shaping devices face issues with powder floating into the nozzle during idle running, leading to liquid ejection failures due to inconsistent flushing operations, especially when using various materials and longer idle times on powder layers.
Innovation Solution
A three-dimensional shaping device with a control unit that executes a first flushing operation when the shaping region area is equal to or greater than a threshold value and a second flushing operation with different conditions when the area is less than the threshold, including higher frequency, voltage, and ejection speed for effective powder removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the head moves on the powder layer for a longer idle time without ejection, then the productivity is improved, but powder floats up and mixes into the nozzle causing liquid ejection failure
Solution Approach 1:
The system performs preliminary detection of powder accumulation in the nozzle before it causes ejection failure. The control unit monitors the idle time and detects when powder has mixed into the nozzle, then executes flushing operation in advance to remove the powder, preventing liquid ejection failure before it occurs.
2Device complexity
If the flushing operation is performed under the same ejection conditions as shaping, then the device complexity is reduced, but the flushing operation is insufficient to remove powder from the nozzle
Solution Approach 1:
The system dynamically adjusts the flushing operation parameters based on the detected powder accumulation state. When powder is detected in the nozzle, the control unit increases the ejection frequency and/or voltage during flushing operation, making the flushing more intense to effectively remove the accumulated powder, rather than using fixed shaping conditions.
3Reliability
If the ejection frequency is increased to improve powder removal, then the powder removal effectiveness is improved, but the energy consumption increases
Solution Approach 1:
The system changes the ejection parameters (frequency and voltage) based on the operational state. During normal shaping, standard parameters are used. During flushing operation when powder accumulation is detected, the control unit increases the ejection frequency and voltage to enhance powder removal. This parameter adjustment is temporary and condition-based, optimizing powder removal effectiveness only when needed while minimizing energy consumption during normal operation.
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
Effectively prevents powder from mixing into the nozzle by optimizing flushing operations based on shaping region area, ensuring reliable liquid ejection even during extended idle times.
Implementation Method 1
a head configured to eject a liquid containing a binder from a nozzle to a shaping region of a three-dimensional shaped object on the powder layer; and a control unit configured to control movement of the head with respect to the shaping table and driving of the head by applying a voltage
Data Source
AI summary
A three-dimensional shaping device includes: a shaping table; a layer forming unit configured to form a powder layer on the shaping table; a head configured to eject a liquid containing a binder from a nozzle to a shaping region; and a control unit configured to control movement of the head with respect to the shaping table and driving of the head by applying a voltage. The control unit executes a first flushing operation when an area of the shaping region is equal to or greater than the threshold value, and executes a second flushing operation when the area of the shaping region is less than the threshold value.