Additive Manufacturing Dispensing Head Non-Linear Path
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Solution Overview
Problem
Existing additive manufacturing methods struggle to directly manufacture components that are securely attached to other components, requiring separate steps for securing them, which increases complexity and costs.
Innovation Solution
A method and system for additive manufacturing where a three-dimensional component is formed directly on a separate substrate using a dispensing head with a non-linear movement path and offset nozzle configuration, allowing the component to be securely attached to the substrate in a single step, utilizing wire feed technology and 3D printing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are manufactured separately and then secured in a separate process step, then manufacturing precision and reliability of individual components are maintained, but device complexity and manufacturing time increase
Solution Approach 1:
The patent merges the component manufacturing process with the attachment process by directly depositing material onto the substrate to form the component in its final attached position. This eliminates the need for separate manufacturing and assembly steps, reducing overall process complexity while maintaining attachment reliability through direct bonding.
Solution Approach 2:
The substrate is prepared in advance with specific surface properties and geometric features that enable direct additive manufacturing attachment. The substrate undergoes preliminary treatment to ensure optimal bonding conditions before the component is deposited, allowing seamless integration of manufacturing and attachment operations.
2Productivity
If additive manufacturing is used to directly form components on substrates, then manufacturing time and process complexity are reduced, but manufacturing precision and attachment quality may be compromised
Solution Approach 1:
The patent applies different quality standards and process parameters to different regions of the deposition process. The nozzle adjusts its deposition parameters locally based on the specific geometric requirements and attachment needs of each area on the substrate, ensuring high precision in critical attachment zones while maintaining overall manufacturing efficiency.
Solution Approach 2:
The deposition process is made dynamic by continuously adjusting deposition parameters such as material flow rate, nozzle temperature, and deposition speed based on real-time feedback about the substrate surface conditions and component geometry requirements. This dynamic adaptation ensures high attachment precision throughout the manufacturing process.
3Device complexity
If a linear movement path is used for the dispensing head, then device simplicity is maintained, but the ability to manufacture complex three-dimensional shapes on non-planar surfaces is limited
Solution Approach 1:
The patent transitions from linear two-dimensional movement to three-dimensional spatial positioning of the dispensing head. The system incorporates vertical movement capability in addition to horizontal movement, allowing the nozzle to access and deposit material on complex non-planar surfaces while maintaining relative device simplicity through the use of standard multi-axis positioning mechanisms.
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 enables direct and secure attachment of three-dimensional components to substrates, reducing the need for separate securing steps, enhancing automation, and resulting in cost savings and time efficiency, particularly suitable for complex applications in fields like aircraft and automotive engineering.
Implementation Method 1
The dispensing head is typically adapted to heat the material inside the dispensing head above its melting temperature or a glass transition temperature
Implementation Method 2
One type of additive manufacturing comprises dispensing or extruding material from which the product is to be manufactured from a nozzle of a dispensing head
Implementation Method 3
hardening of the dispensed material may be effected automatically by means of a suitable choice of the temperature and of the material
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
Method of manufacturing a three-dimensional object (22) by means of additive manufacturing as well as to a corresponding system for carrying out the method and a dispensing head for use in the method. The three-dimensional object (22) comprises a three-dimensional component (21). The method comprises providing a substrate (20, 20"), and successively forming on the substrate (20, 20") a plurality of layers (23, 23'), wherein each layer is formed in a pattern corresponding to a three-dimensional component (21) being manufactured and wherein each layer (23, 23') is formed by dispensing a curable material from a nozzle (5, 5') of a dispensing head (4, 4', 4") and subsequently curing the curable material (8). The three-dimensional object (22) is constituted by the combination of the substrate (20, 20") and the three-dimensional component (21), wherein the substrate (20, 20") has a non-planar surface portion and the three-dimensional component (21) is formed at least in part on the non-planar surface portion in such a manner that it is fixedly secured to the substrate (20, 20"). During forming of at least one of the layers (23, 23') and/or between forming of at least two adjacent ones of the layers (23, 23') a relative movement between the substrate (20, 20") and the dispensing head (4, 4', 4'') is effected such that in a substrate coordinate system the dispensing head (4, 4', 4") moves along a non-linear path over the non-planar surface portion.