Direct Wire Embedding Head for 3D Printed Parts
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Solution Overview
Problem
Current 3D printing technologies lack an efficient method for automatically dispensing and embedding wires or filaments into three-dimensional printed parts, particularly in starting and terminating wire patterns, and handling inconsistent part geometries.
Innovation Solution
A direct wire embedding head fixed on an automation motion system, equipped with sensors and heating/cooling mechanisms, allows for automatic creation of wire patterns on and within 3D printed parts by encapsulating wire ends in melted plastic and using a cutting knife for termination, while sensors adjust the head's position to maintain consistent embedding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual wire embedding is used in 3D printing, then flexibility and adaptability are maintained, but productivity and manufacturing precision deteriorate
Solution Approach 1:
The patent merges the wire embedding function with the 3D printing process by integrating a wire feeder and embedding head directly into the printing system. This allows wires to be embedded during the printing process itself, eliminating separate post-processing steps and significantly improving productivity without requiring complex external equipment
Solution Approach 2:
The embedding head is designed to perform multiple functions: it can embed wires during printing, continue embedding after printing completes, and adapt to different wire types and patterns. This multi-functionality maintains operational flexibility while automating the process, resolving the contradiction between productivity improvement and system complexity
2Productivity
If automated wire embedding is implemented, then productivity improves, but manufacturing precision and reliability worsen due to difficulty in starting and terminating wire patterns
Solution Approach 1:
The system performs preliminary actions by pre-positioning the wire in the embedding head before the printing process begins, and by pre-planning the wire path based on the 3D model. This ensures that wire patterns start and terminate at precise locations with high manufacturing precision while maintaining automation benefits
Solution Approach 2:
The embedding system incorporates feedback mechanisms that monitor wire embedding in real-time, allowing the system to adjust and maintain precise wire patterns during automated operation. This feedback control ensures manufacturing precision is maintained throughout the automated process
3Adaptability or versatility
If wire embedding is performed on non-planar surfaces, then adaptability improves, but manufacturing precision deteriorates due to surface geometry variations
Solution Approach 1:
The embedding head is designed with dynamic positioning capabilities that allow it to adapt to varying surface geometries. The system can adjust its position and orientation in real-time to accommodate non-planar surfaces while maintaining consistent embedding precision through automated control
Solution Approach 2:
The system applies local quality control by adjusting embedding parameters specifically for different surface regions. The embedding head can modify its operation based on the local surface geometry it encounters, ensuring precision is maintained across varied surfaces while maintaining high adaptability
4Productivity
If continuous wire embedding is performed, then productivity improves, but reliability worsens due to wire tension and positioning challenges
Solution Approach 1:
The wire feeding mechanism uses periodic action with controlled tensioning and payout during embedding. The system rhythmically adjusts wire tension and feeding rate during continuous embedding operations, maintaining wire quality and positioning accuracy throughout the process while enabling continuous high-productivity operation
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 automated embedding of wire patterns as interconnections for electronic components, electromagnetic devices, or mechanical reinforcement, addressing the challenges of starting and terminating patterns and accommodating non-planar surfaces.
Implementation Method 1
embedding a first end of the wire in the plastic material by locally melting or softening the plastic and placing the wire in the molten material
Implementation Method 2
cooling the molten material to encapsulate and fix the end of the wire in the plastic
Data Source
AI summary
An apparatus, system, and method for automatically dispensing and embedding components into three-dimensional parts. In an example embodiment, a direct wire embedding head can be fixed on an automation motion system. The direct wire embedding head begins and terminates an embedded wire pattern on a layer or on a surface of a three-dimensional part in order to automatically create the embedded wire pattern. A sensor is located on an embedding surface wherein the embedded wire pattern is embedded. The sensor can measure the distance between the direct wire embedding head and the embedding surface. A predefined distance can be maintained to ensure successful embedding results for the embedded wire pattern by automatically adjusting a position of the direct wire embedding head in response to feedback from the sensor.