Ejector Device for 3D Printing Molten Aluminum
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Solution Overview
Problem
Existing 3D printing technologies using molten aluminum result in large drop sizes, leading to porosity, uneven build surfaces, and shape inconsistencies, which degrade the physical properties and appearance of printed objects, making it difficult to print fine details.
Innovation Solution
A 3D printer with an ejector device featuring an array of conduits with electrodes and a magnetic field source, allowing for the mixing and precise ejection of print materials using electromagnetic forces, enabling the creation of smaller droplet sizes and improved print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electromagnetic pulses are used to eject molten aluminum drops, then high volume throughput is achieved, but drop size becomes large (0.5 mm or larger)
Solution Approach 1:
The ejector device is divided into multiple independent ejector conduits (first, second, third conduits) that can be controlled separately, allowing selective ejection of smaller droplets while maintaining overall high throughput capability
Solution Approach 2:
Different regions of the ejector device have specialized functions - some conduits are optimized for mixing materials while others are optimized for precise droplet ejection, allowing local optimization of both throughput and precision
2Productivity
If large drop sizes are used for high volume throughput, then fabrication speed is improved, but porosity and shape inconsistencies increase
Solution Approach 1:
The system dynamically adjusts droplet size and ejection parameters based on the specific printing requirements, allowing optimization of both fabrication speed and object quality for different stages or regions of the build process
Solution Approach 2:
The electromagnetic pulse parameters (amplitude, duration, frequency) are precisely controlled and adjusted to produce consistent smaller droplet sizes, eliminating the porosity and shape inconsistencies associated with larger drops while maintaining high fabrication speed
3Manufacturing precision
If electromagnetic forces are used for precise droplet ejection, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical droplet ejection systems with electromagnetic forces, achieving precise droplet size control and ejection without the mechanical complexity of moving parts, valves, or pumps
Solution Approach 2:
By controlling electromagnetic pulse parameters (voltage, current, duration), the system achieves precise control over droplet ejection without adding mechanical complexity, using field-based control instead of mechanical actuation
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
The solution allows for the selective jetting of small droplet sizes, enabling the printing of fine features and improving the physical properties and appearance of 3D objects by reducing porosity and surface irregularities.
Implementation Method 1
A magnetic field source is sufficiently proximate the second end of the plurality of ejector conduits so as to generate a flux region disposed within the ejector nozzle of the plurality of ejector conduits during operation of the 3D printer
Implementation Method 2
A current pulse generating system is in electrical connection with the first electrode and the second electrode of the plurality of ejector conduits
Data Source
AI summary
A 3D printer includes an ejector device for mixing and ejecting print material. The ejector device includes a substrate and a plurality of ejector conduits on the substrate. The ejector conduits are arranged in an array. Each ejector conduit includes a first passageway fluidly connecting a first end of the ejector conduit to a conduit junction. The first end is configured to accept a first print material. Each ejector conduit also includes a second passageway fluidly connecting a second end of the ejector conduit to the conduit junction. The second end is configured to accept a second print material. Each ejector conduit also includes a third passageway fluidly connecting a third end of the ejector conduit to the conduit junction. The third end includes an ejector nozzle. The ejector nozzle includes a first electrode and a second electrode.