Curved Wire Embedding Head for 3D Printing
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Solution Overview
Problem
Inconsistencies such as wire damage, breakage, out-of-tolerance placement, and unacceptable depth occur when embedding wires into a substrate during 3D printing, due to the perpendicular orientation of wire output from existing line embedding heads, which affects the trajectory and resistance of wire embedding.
Innovation Solution
A line embedding head with a curved channel that outputs the wire at an angle relative to the substrate, allowing for deeper embedding with controlled resistance, and accommodating wires of varying stiffness by adjusting the angle and using low-friction materials for the channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wire is output perpendicular to the embedding head, then the embedding process is simple, but wire damage and breakage occur due to poor trajectory control
Solution Approach 1:
The patent applies a curved channel instead of a straight perpendicular output, allowing the wire to exit at an angled trajectory that reduces damage and breakage while maintaining process simplicity
2Device complexity
If wire is output perpendicular to the embedding head, then the device structure is simple, but wire placement precision is poor
Solution Approach 1:
The curved channel geometry enables precise control over wire exit angle and trajectory, improving placement accuracy without complicating the overall device structure
Solution Approach 2:
The patent changes the output angle parameter from perpendicular (90 degrees) to an angled configuration, allowing optimization of wire placement precision while maintaining structural simplicity
3Device complexity
If wire is output perpendicular to the embedding head, then the embedding depth is limited, but the device structure remains simple
Solution Approach 1:
The curved channel configuration enables deeper embedding by optimizing the wire trajectory angle, achieving better depth control without increasing device complexity
4Ease of manufacture
If standard channel materials are used, then manufacturing is easy, but friction causes inconsistencies in wire embedding
Solution Approach 1:
The patent changes the material parameter of the channel to have low-friction properties, reducing friction-induced inconsistencies while maintaining ease of manufacture
Solution Approach 2:
The channel is coated with a low-friction material layer that reduces friction between the wire and channel walls, improving embedding consistency without complicating manufacturing
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 configuration reduces inconsistencies in wire embedding, enabling precise control over wire depth and resistance, facilitating the use of low-stiffness wires and improving the embedding process in 3D printing.
Implementation Method 1
The line embedding head begins and terminates an embedded line pattern on a layer or on a surface of a substrate such that the embedded line pattern is automatically created
Data Source
AI summary
A method for embedding a line in a substrate. A line embedding head in positioned relative to a surface of the substrate. The line from an output port in the line embedding head is output at an angle relative to the embedding head such that the line is embedded in the substrate.