Coaxial Cable Embedding in 3D Printed Thermoplastic Filaments
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Solution Overview
Problem
Current additive manufacturing technologies lack the ability to integrate electrical cables into 3D printed components in a flexible and configuration-independent manner, limiting the complexity and customization of electrical systems within additively manufactured parts.
Innovation Solution
An additive manufacturing device with a coaxial merging station and extruder that coats and embeds electrical cables with functional materials like insulators, shielding, and protectors into thermoplastic filaments, allowing for selective integration of electrical cables with varying configurations and material layers, enabling the creation of components with embedded electrical systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical cables are integrated into 3D printed components using current additive manufacturing technologies, then the electrical functionality is achieved, but the flexibility and customization of cable configurations are limited
Solution Approach 1:
The manufacturing process is divided into distinct segments: first coating the cable core with functional materials at the coaxial merging station, then embedding the pre-coated cable into the thermoplastic filament at the extruder. This segmentation allows each station to specialize in specific tasks, improving flexibility while managing complexity through modular process design
Solution Approach 2:
The cable core is preliminarily coated with functional materials (insulators, shielding, protectors) at the coaxial merging station before being embedded in the thermoplastic filament. This preliminary action enables customization of cable configurations and material combinations without compromising the final component's shape or orientation, directly addressing the flexibility limitation
2Reliability
If multiple functional materials are added to the cable core to provide insulation, shielding, and protection, then the cable functionality is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
Multiple functional materials (electric insulator, electromagnetic shielding, thermal insulator, mechanical protector) are merged into a single coaxial coating process at the merging station. The materials are applied in sequential layers around the cable core in one continuous operation, enhancing cable functionality while avoiding the need for separate manufacturing steps for each material layer
Solution Approach 2:
The coaxial merging station is designed as a universal platform that can handle multiple types of functional materials and apply them to various cable configurations. This multi-functional capability allows the same device to provide insulation, shielding, and protection through varying material combinations and layer thicknesses, enhancing reliability without proportionally increasing device complexity
3Ease of manufacture
If cables are embedded in thermoplastic filaments during extrusion, then the integration is achieved, but the ability to maintain sharp turns and tailored configurations is compromised
Solution Approach 1:
The thermoplastic filament material's temperature is changed to a malleable state during extrusion, allowing the cable to be embedded without compromising its ability to maintain sharp turns and tailored configurations. The controlled temperature parameter enables the material to be sufficiently soft for embedding while still supporting complex cable geometries in the final cooled component
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
Enables the flexible integration of electrical cables with tailored material combinations and configurations, such as sharp turns, within 3D printed components, enhancing the flexibility and complexity of electrical systems without compromising shape or orientation.
Implementation Method 1
The coaxial merging station is configured to receive a cable core, the cable core comprising at least one electrical conductor, and to coaxially coat the cable core with at least one functional cable material made malleable by application of temperature
Implementation Method 2
a coaxial extruder configured to receive the electrical cable from the coaxial merging station, to coaxially embed the electrical cable in a thermoplastic filament material made malleable by application of temperature
Implementation Method 3
the AM device may further comprise at least one laser source configured to heat up the thermoplastic filament material and/or the at least one functional cable material
Data Source
Figure 1~2
Figure 3~4
AI summary
An additive manufacturing device for printing of a thermoplastic filament with an embedded electrical cable comprises a coaxial merging station configured to receive a cable core, the cable core comprising at least one electrical conductor, and to coaxially coat the cable core with at least one functional cable material to form an electrical cable, the at least one functional cable material being made malleable by application of temperature and comprising at least one of an electric insulator, an electromagnetic shielding, a thermal insulator and a mechanical protector; and a coaxial extruder configured to receive the electrical cable from the coaxial merging station, to coaxially embed the electrical cable in a thermoplastic filament material made malleable by application of temperature and to extrude the thermoplastic filament material with the embedded electrical cable as a thermoplastic filament.