CNC Spindle Filament Extrusion Tool for Large-Volume Additive Manufacturing
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Solution Overview
Problem
CNC machines lack an affordable and efficient method for additive manufacturing, as separate 3D printing devices are expensive and provide limited work volumes, limiting the ability to produce larger parts within industrial settings.
Innovation Solution
An additive manufacturing tool is developed that couples to a CNC machine's spindle, featuring drive wheels, a heating element, and a nozzle system to extrude melted filament, allowing for the creation of larger parts within the CNC machine's workspace.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate 3D printing device is used for additive manufacturing, then additive manufacturing capability is provided, but the cost is high and the work volume is limited
Solution Approach 1:
The patent combines additive manufacturing functionality with an existing CNC machine by integrating a filament feed system, heating element, and extrusion nozzle into the CNC machine's workspace. This merging eliminates the need for a separate 3D printer while utilizing the CNC machine's larger work volume and positioning capabilities.
Solution Approach 2:
The CNC machine is transformed into a multi-functional device that can perform both traditional subtractive manufacturing and additive manufacturing operations. The tool holder and spindle system are adapted to accommodate filament feeding and extrusion components, allowing the same machine to serve multiple manufacturing purposes.
2Productivity
If drive wheels compress filament against a drive disc, then filament is drawn through the tool, but the drive wheels must be movable between engaged and disengaged positions
Solution Approach 1:
The drive wheels are designed to be movable between engaged and disengaged positions rather than fixed. This dynamic configuration allows the drive wheels to engage the filament during feeding operations and disengage when filament changes or removal is needed, providing operational flexibility while maintaining efficient filament transport when engaged.
Solution Approach 2:
The system includes automatic filament detection and drive wheel engagement/disengagement mechanisms that operate without manual intervention. The drive wheels automatically engage when filament is detected and disengage when filament is depleted or needs replacement, reducing operational complexity despite the movable mechanism.
3Productivity
If the heating element melts the filament in the nozzle, then extruded material is delivered, but the filament must be routed around the drive disc
Solution Approach 1:
The filament routing system utilizes three-dimensional space within the tool housing to guide the filament from the feed mechanism around the drive disc to the heating element and nozzle. This spatial arrangement allows the filament to follow a complex path through different dimensions rather than requiring a long linear route, maintaining compact tool design while ensuring proper filament positioning for extrusion.
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 enables CNC machines to perform additive manufacturing, expanding their work volume and reducing the need for separate 3D printing devices, making it more cost-effective and versatile for producing larger parts.
Implementation Method 1
heat transferred from the heating element to the nozzle melts the filament
Implementation Method 2
heat transferred from the heating element to the nozzle melts the filament so that the filament flows through the outlet opening
Implementation Method 3
the plurality of drive wheels compress filament from a filament source against a drive disc and a disengaged position wherein the plurality of drive wheels are spaced apart from the filament
Data Source
AI summary
An additive manufacturing tool configured to couple to a spindle of a CNC machine, comprises a plurality of drive wheels movable between an engaged position wherein they compress filament from a filament source against a drive disc and a disengaged position wherein they are spaced apart from the filament, and a delivery assembly including a heating element and a nozzle having an outlet opening. When the plurality of drive wheels are in the engaged position and the drive disc is rotated, the filament is drawn into the tool from the filament source and routed around the drive disc to the nozzle, where heat transferred from the heating element to the nozzle melts the filament so that the filament flows through the outlet opening.