3D Printer Dual Stage Cutting and Extrusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printers face challenges in precisely forming objects of desired shapes and require separate cutting or grinding processes, which are time-consuming and costly due to their low speed and the formation of stair-shaped portions between layers.
Innovation Solution
A 3D printer with a dual stage structure featuring an extrusion unit and a cutting unit positioned above a stacking base unit, allowing for simultaneous layer formation and cutting or grinding operations with variable distances between units, enabling the cutting unit to move vertically and rotate, thus performing cutting or grinding concurrently with layer deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate cutting process is performed after layer-by-layer object formation, then shape precision is improved by removing stair-shaped portions, but production time increases and manufacturing cost increases
Solution Approach 1:
The patent combines the cutting unit with the extrusion unit in a dual-stage configuration, allowing cutting operations to be performed simultaneously with layer deposition. The cutting unit is positioned between the extrusion unit and stacking base unit, enabling integrated manufacturing where cutting and extrusion occur in parallel rather than sequentially, thus reducing production time while maintaining shape precision
Solution Approach 2:
The cutting unit performs preliminary cutting actions on newly deposited layers immediately after extrusion while the object is still being formed. This preliminary action removes stair-shaped portions during the manufacturing process itself, eliminating the need for separate post-processing and reducing total production time
2Manufacturing precision
If a separate cutting process is performed after layer-by-layer object formation, then shape precision is improved by removing stair-shaped portions, but manufacturing cost increases
Solution Approach 1:
The patent merges the cutting unit with the extrusion unit into a single integrated system. By combining these functions in a dual-stage configuration, the patent eliminates the need for separate cutting equipment and post-processing operations, thereby reducing manufacturing costs while maintaining the ability to achieve precise shapes through simultaneous cutting and extrusion
Solution Approach 2:
The integrated system performs multiple functions within a single manufacturing apparatus. The cutting unit can perform both rough cutting and fine grinding operations on different layers simultaneously with extrusion, providing multi-functionality that reduces the need for separate specialized equipment and lowers overall manufacturing costs
3Device complexity
If the cutting unit is fixed in position, then device complexity is reduced, but the ability to perform simultaneous cutting and extrusion is limited
Solution Approach 1:
The cutting unit is designed with vertical movability along the frame, allowing it to dynamically adjust its position between the extrusion unit and stacking base unit. This dynamic positioning enables the cutting unit to access different layers during simultaneous cutting and extrusion operations, maintaining productivity while keeping the overall structure relatively simple through guided linear motion
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 allows for the rapid and precise formation of objects by integrating cutting or grinding into the layering process, reducing production time and costs by eliminating the need for separate cutting processes and improving shape accuracy.
Implementation Method 1
an extrusion unit configured to extrude a raw material
Implementation Method 2
a cutting unit between the stacking base unit and the extrusion unit and configured to grind or cut the object
Data Source
AI summary
A 3D printer has a dual stage structure and includes: a frame; an extrusion unit having a nozzle configured to extrude a raw material; a stacking base unit positioned under the extrusion unit and configured to receive the raw material on a surface thereof so that an object is formed in a layer-by-layer manner on the surface; and a cutting unit positioned between the stacking base unit and the extrusion unit and configured to grind or cut the object formed on the surface of the stacking base unit, wherein the frame is configured to be connected to outer sides of the stacking base unit, the extrusion unit, and the cutting unit, the stacking base unit and the cutting unit are configured to be vertically movable along the frame, and the nozzle is configured to be movable on a plane.