Concave FDM Filament Geometry for Faster Moisture Drying
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Solution Overview
Problem
Drying filaments used in FDM 3D printing is energy- and time-consuming due to their hygroscopic nature, leading to issues like bubble formation, extrusion problems, and poor adhesion, which affects the quality and mechanical integrity of printed objects.
Innovation Solution
Designing filaments with a concave cross section that increases the surface area, reducing drying time by allowing for faster moisture evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filament is dried in an oven to prevent moisture absorption, then printed object quality and mechanical integrity are improved, but energy consumption and drying time increase
Solution Approach 1:
The invention changes the geometric parameters of the filament by introducing a concave cross-section instead of a conventional circular one. This parameter change increases the surface area to volume ratio, which accelerates moisture evaporation during drying, thereby reducing drying time while maintaining printed object quality
Solution Approach 2:
The invention transitions from a conventional circular cross-section (one-dimensional symmetry) to a concave cross-section with multiple facets. This dimensional change in the cross-sectional geometry creates additional surface area that exposes more internal moisture to the external environment, facilitating faster drying without compromising structural integrity
2Reliability
If filament is dried in an oven to prevent moisture absorption, then printed object quality and mechanical integrity are improved, but energy consumption increases
Solution Approach 1:
The invention changes the geometric parameters of the filament by introducing a concave cross-section instead of a conventional circular one. This parameter change increases the surface area to volume ratio, which accelerates moisture evaporation during drying, thereby reducing drying time and associated energy consumption while maintaining printed object quality
Solution Approach 2:
The invention transitions from a conventional circular cross-section (one-dimensional symmetry) to a concave cross-section with multiple facets. This dimensional change in the cross-sectional geometry creates additional surface area that exposes more internal moisture to the external environment, facilitating faster drying and reducing the energy required for the drying process
3Ease of manufacture
If conventional circular filament is used, then manufacturing is simple, but drying time is long due to lower surface area
Solution Approach 1:
The invention changes the geometric parameters of the filament by introducing a concave cross-section instead of a conventional circular one. This parameter change increases the surface area to volume ratio, which accelerates moisture evaporation during drying, thereby reducing drying time while maintaining manufacturing feasibility through extrusion processes
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
The concave cross section filaments reduce drying time, enhancing the quality and mechanical integrity of printed objects by minimizing moisture absorption-related defects.
Implementation Method 1
reducing drying time by allowing for faster moisture evaporation
Data Source
Figure 1
Figure 2(a)~2(d)
Figure 3(a)~3(c)
AI summary
The invention relates to a method of manufacturing a 3D item (910) by means of fused deposition modelling using a 3D printer (100). The method comprises the step of layer-wise depositing a 3D printable material to provide the 3D item (910) comprising layers (920) of 3D printed material (921). The 3D printable material is a filament (200) comprising a thermoplastic material. The filament (200) has an axis of elongation (210). Perpendicular to the axis of elongation (210), the filament (200) has a cross section with a concave shape. The filament (200) may have a filament center portion (241) and a plurality of filament extensions (242), wherein the filament center portion (241) has a filament center axis that coincides with the axis of elongation (210) of the filament (200), and wherein each filament extension (242) has an extension length and extends from the filament center portion (241) in an extension direction perpendicular to the filament center axis. The use of the aforementioned filament (200) results in a reduced drying time, which in turn makes the method a less energy- and time-consuming process.