3D Printing Color Mixing Nozzle with Distribution Elements
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Solution Overview
Problem
FDM 3D printing technologies face challenges in creating materials with varying physical and chemical properties, such as color, optical effects, and thermal conductivity, as molecular-level mixing is difficult to achieve, limiting the ability to produce complex and precise variations within a single printed item without requiring multiple filaments with different properties.
Innovation Solution
A multi-channel mixing head with distribution elements and a combination chamber that combines different 3D printable materials with varying properties, allowing for controlled distribution and exit through a nozzle, enabling the creation of materials with desired properties without the need for multiple filaments, by distributing materials in small regions on the surface or in volume, resulting in uniform effects like color or optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional FDM extrusion method is used, then the printing process is simple and fast, but molecular-level mixing of materials is difficult to achieve, limiting material property variation
Solution Approach 1:
The extrusion system is segmented into multiple independent distribution elements (first, second, third distribution elements) that can independently deliver different materials. Each distribution element has its own material inlet and outlet, allowing separate control of material flow while maintaining overall system simplicity for achieving complex material variations
Solution Approach 2:
Different materials are delivered to specific local regions through the distribution elements positioned at different locations (first, second, third outlets). This allows spatial variation of material properties within the printed object, creating local property gradients without requiring complete molecular mixing throughout the entire material stream
2Manufacturing precision
If multiple filaments with different properties are used to achieve material variations, then precise property control is possible, but the system requires extensive material inventory and complex filament management
Solution Approach 1:
The extrusion system is designed with multi-functionality to deliver different materials through a single integrated nozzle assembly. The distribution elements can switch between delivering different materials (first, second, third materials) through different outlets, eliminating the need for multiple dedicated nozzles or complex filament switching mechanisms while maintaining precise property control
Solution Approach 2:
The distribution elements act as intermediary components between the material sources and the final extrusion point. These intermediaries control material flow and mixing locally, enabling precise property control at the point of deposition without requiring complex upstream filament management or inventory systems
3Stability of the object's composition
If materials are mixed at molecular level to achieve uniform properties, then homogeneous material characteristics are obtained, but the mixing process becomes extremely difficult and time-consuming in FDM printing
Solution Approach 1:
Instead of attempting molecular-level mixing of all materials together, the system segments the material delivery into distinct streams through separate distribution elements. Each material maintains its identity until the point of deposition, where controlled mixing occurs only where needed, preserving printing speed while achieving composition stability through precise spatial distribution
Solution Approach 2:
The system achieves material homogeneity through local quality control at the deposition interface rather than through bulk molecular mixing. By positioning distribution elements to deliver materials in specific patterns and proportions directly at the print head, the system creates locally homogeneous regions that build up to overall compositional stability in the printed object
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 approach allows for the production of 3D printed items with tunable properties and precise color or optical effects, achieving uniformity and stepless transitions, which were previously difficult to achieve with traditional FDM methods, without the necessity of having all intermediate combinations of materials on stock.
Implementation Method 1
each distribution element comprise a flow-through chamber with an inlet for a 3D printable material and a number of k outlets to the combination chamber... each distribution element being arranged to distribute the 3D printable material by the plurality of k outlets
Implementation Method 2
the combination chamber is configured downstream of the distribution elements and upstream of the printer nozzle... combining different 3D printable materials with varying properties, allowing for controlled distribution and exit through a nozzle
Data Source
AI summary
The invention provides a printer head (501) for a 3D printer, the printer head (501) comprising n distribution elements (510), wherein n≥2, a combination chamber (520), and a printer nozzle (502), wherein the combination chamber (520) is configured downstream of the distribution elements (510) and upstream of the printer nozzle (502), wherein each distribution element (510) comprise a flow-through chamber (511) with an inlet (512) and a plurality of k outlets (513) to the combination chamber (520), wherein k≥4, wherein the outlets (513) of the distribution elements (510) are configured such that a plurality of outlets (513) of a distribution element (510) have outlets (513) of another distribution element (510) as nearest neighbors.