CNC Spindle-Powered Extruder for Additive Manufacturing
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Solution Overview
Problem
CNC machines lack an efficient and cost-effective method for additive manufacturing, as separate 3D printing devices are expensive and provide limited work volumes, limiting the integration of additive and subtractive manufacturing processes.
Innovation Solution
A self-contained extruder unit that couples with a CNC machine's spindle, utilizing the spindle's rotational speed to control material processing functions, including extrusion, through a holder and generator system, enabling both additive and subtractive manufacturing within a unified process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate 3D printing device is used for additive manufacturing, then material deposition capability is provided, but device complexity and cost increase
Solution Approach 1:
The patent combines additive manufacturing (extrusion) and subtractive manufacturing (milling) capabilities into a single integrated tool that attaches to the CNC machine spindle. The tool holder receives both an extruder device and a milling tool, allowing both functions to be performed by one machine system rather than requiring separate 3D printer and CNC machine.
Solution Approach 2:
The tool holder is designed with universal adaptability to accommodate multiple tool types including extruders and milling tools. The holder can be selectively coupled with different tools based on whether additive or subtractive manufacturing is required, making the CNC machine system multi-functional and eliminating the need for separate dedicated devices.
2Adaptability or versatility
If a separate 3D printing device is used, then material deposition is enabled, but work volume is limited
Solution Approach 1:
By merging the extrusion function with the CNC machine system, the patent enables additive manufacturing within the CNC machine's larger workspace. This integrated approach allows parts to be built using the extruder and then subsequently machined with the milling tool in the same machine, effectively utilizing the CNC machine's larger work volume rather than being constrained by a separate 3D printer's build chamber.
3Device complexity
If CNC machine spindle rotation is used to control extruder functions, then device complexity is reduced, but control precision requirements increase
Solution Approach 1:
The extruder device is designed to be self-powered by utilizing the rotational motion of the CNC machine spindle through a generator. The generator converts the mechanical rotational energy from the spindle into electrical power that operates the extruder's motor and control systems. This eliminates the need for a separate power source and reduces overall system complexity.
Solution Approach 2:
The system incorporates a sensor that monitors the rotational speed of the spindle and provides feedback to the control system. This feedback mechanism allows the extruder's operation to be precisely controlled based on the actual spindle speed, ensuring accurate synchronization between material deposition and machine motion while compensating for variations in rotational speed.
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
This solution allows for a larger 3D work volume, reducing the need for separate 3D printing devices and enabling a combined additive/subtractive manufacturing process, enhancing the capabilities of CNC machines by using the spindle's rotation to power and control the extruder for material deposition and removal.
Implementation Method 1
a generator supported by the holder that converts rotary motion of the spindle into power for the extruder
Data Source
AI summary
An interchangeable unit adapted to couple to a computer numerical control (“CNC”) machine is disclosed comprising a holder that couples to a spindle of the CNC machine, a controller, wherein said controller is configured to receive the rotational speed of the spindle as an input, and a material processing unit, wherein said material processing unit executes a first function in response to a first rotational speed range of the spindle and executes a second function in response to a second rotational speed range of the spindle.