Drop-draw extrusion nozzle for precise filament diameter control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional Fused Deposition Modeling (FDM) additive manufacturing techniques are limited by slower manufacturing times, larger filament diameters, inability to control physical properties with precision, and the requirement for flat substrates, which restricts the fabrication of complex structures with tailored properties.
Innovation Solution
The drop-draw extrusion (DD/E) method, which involves depositing anchors on a substrate, creating a vertical space between the nozzle and the substrate, and drawing filaments between anchors to form a two-dimensional network of interconnected filaments, allowing for precise control of filament diameter, tensile strength, and architecture on non-flat substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional FDM deposits material in close proximity to the substrate, then material bonding is achieved, but manufacturing speed is slow and filament diameter is large
Solution Approach 1:
The patent introduces a vertical dimension by lifting the nozzle away from the substrate during filament deposition. Instead of depositing material in close proximity (2D plane), the nozzle moves to a elevated position (3D space) to draw thin filaments through air, then returns to deposit them. This dimensional change enables both high speed and precise filament diameter control.
Solution Approach 2:
The patent performs preliminary actions by first creating anchor points on the substrate, then lifting the nozzle to a predetermined height before drawing and depositing filaments. This pre-positioning of anchors and nozzle elevation allows for rapid, controlled filament deposition without continuous substrate contact, improving both speed and precision.
2Adaptability or versatility
If conventional FDM uses close proximity deposition, then material bonding occurs, but the process requires flat substrates and cannot handle non-flat surfaces
Solution Approach 1:
By elevating the nozzle into the vertical dimension, the patent creates clearance between the nozzle and substrate surface. This allows the nozzle to traverse above non-flat substrates without collision, enabling deposition on curved, textured, or irregular surfaces while maintaining process reliability through controlled anchor-point-to-anchor-point deposition.
3Productivity
If conventional FDM deposits layers sequentially in close proximity, then layer bonding is achieved, but manufacturing time increases
Solution Approach 1:
The patent creates anchor points in advance on the substrate surface, then rapidly deposits filaments between these pre-positioned anchors by lifting and moving the nozzle. This preliminary anchoring enables fast filament placement while ensuring reliable bonding at critical anchor points, balancing speed and strength.
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 rapid fabrication of structures with tailored properties, achieving higher manufacturing speeds, smaller filament diameters, and the ability to create complex geometries on non-flat surfaces, improving the reliability and versatility of additive manufacturing.
Implementation Method 1
heating the thermoplastic material to a melting temperature
Implementation Method 2
drawing a filament of the material extending from the first anchor to the second anchor
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
A drop draw and extrusion method that creates anchor points (116a, 116c) around, within, or around and within, the region where a two dimensional fibrous architecture is deposited. Between the anchor points, a nozzle (108) translates at high speeds to draw, extrude, or draw and extrude (depending on the print settings), a filament (600) from the nozzle and build a two dimensional network of filaments connected by the anchors. Webbed architectures fabricated using the methods described herein exhibit superior structural properties.