Curved-Surface 3D Printing With Multi-Axis Nozzle Control
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Solution Overview
Problem
Existing three-dimensional printing technologies struggle to effectively print on curved surfaces without compromising the quality and precision of the printed structures.
Innovation Solution
A method and apparatus for three-dimensional printing on curved surfaces using a nozzle that moves in multiple directions, including vertical and horizontal axes, to attach composite yarn to the surface, allowing for the formation of three-dimensional structures on articles with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional three-dimensional printing methods are used on curved surfaces, then the printing process can be simplified, but the quality and precision of the printed structures deteriorate
Solution Approach 1:
The printing system dynamically adjusts the nozzle position, movement speed, and printing parameters in real-time based on the curvature of the surface being printed. The nozzle moves along multiple axes (vertical and horizontal) to adapt to varying surface geometries, maintaining optimal print quality across curved surfaces without requiring complex pre-processing of the surface
Solution Approach 2:
The system changes printing parameters such as nozzle-to-surface distance, deposition rate, and layer thickness dynamically during the printing process based on the local curvature of the surface. This allows the same printing system to handle various curved surfaces with different radii and geometries while maintaining consistent print quality
2Manufacturing precision
If a flat substrate is required for three-dimensional printing, then printing precision is maintained, but the versatility and applicability to various shapes deteriorate
Solution Approach 1:
The printing system is designed to print on multiple types of surfaces (flat and curved) with varying geometries using the same apparatus. The nozzle assembly can move along multiple axes and adjust its orientation to accommodate different surface shapes, making the system universally applicable to various articles including footwear, apparel, and other three-dimensional objects without requiring specialized equipment for each surface type
Solution Approach 2:
The system transitions from traditional two-dimensional flat surface printing to three-dimensional curved surface printing by adding vertical movement capability to the nozzle. This allows the nozzle to follow the contours of curved surfaces while maintaining precise control over material deposition, effectively extending the printing capability into the third dimension
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 precise and high-quality printing on articles with curved surfaces, accommodating various shapes and sizes, including footwear and apparel, without the need for a flat substrate, enhancing the versatility and accuracy of three-dimensional printing.
Implementation Method 1
By moving the nozzle in a direction aligned with the vertical axis over the print surface and simultaneously moving the nozzle in a direction aligned with the first horizontal axis over the print surface, the print material can be attached to a print surface of the article
Data Source
AI summary
A method and apparatus for printing onto a curved surface of an article are disclosed. An embodiment of a method may include receiving the article and extruding a composite yarn from a nozzle. A method may include attaching the composite yarn to the curved surface by moving the nozzle in a direction aligned with a first axis and a direction aligned with second axis along the curved surface. The first axis may be approximately normal to the print surface and the second axis may be approximately normal to the first direction. The article may be repositioned during printing to accommodate nozzle movement.