Electromagnetic Printer Jetting Mechanism for Fine Droplet Control
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Solution Overview
Problem
Existing 3D printers using molten aluminum produce objects with high porosity, uneven build surfaces, and shape inconsistencies due to large drop sizes, leading to poor tensile strength and inability to print fine details.
Innovation Solution
A printer jetting mechanism employing an ejector device with electrodes and a magnetic field source to generate a flux region within the ejector nozzle, using electrical current and magnetic forces to control the ejection of print material, allowing for small droplet sizes and high throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large drop size is used for high volume throughput, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent changes the physical parameters of droplet ejection by introducing electromagnetic fields (current pulses and magnetic flux) to control droplet formation. This enables precise control of droplet size and velocity, allowing small droplets to be ejected at high speeds, thus achieving both high productivity and high manufacturing precision simultaneously
2Productivity
If large drop size is used for high volume throughput, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The electromagnetic control mechanism changes the parameters of droplet ejection, enabling consistent formation of small droplets with controlled velocity. The current pulse and magnetic flux work together to ensure uniform droplet size and spacing, achieving high shape consistency while maintaining high ejection rates for improved productivity
3Productivity
If large drop size is used for high volume throughput, then productivity is improved, but reliability deteriorates
Solution Approach 1:
By changing the ejection parameters through electromagnetic control, the patent produces small, uniform droplets that reduce porosity in the printed object. The precise control over droplet size and placement ensures proper material deposition and bonding, improving the reliability and tensile strength of the final product while maintaining high production volume
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 the production of 3D objects with improved surface quality and fine detail capabilities by controlling droplet size and velocity, reducing porosity and shape inconsistencies.
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
Data Source
AI summary
A 3D printer includes an ejector device including a substrate and a plurality of ejector conduits on the substrate. Each ejector conduit includes: a first end positioned to accept a print material and a second end including an ejector nozzle. The ejector nozzle includes a first electrode and a second electrode, and a passageway for allowing the print material to flow from the first end to the second end. A current pulse generating system is in electrical connection with the first electrode and the second electrode of the plurality of ejector conduits. A magnetic field source is 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.