3D Printing Extruder Local Cooling for Overhangs
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Solution Overview
Problem
Inexpensive 3D printers struggle to produce three-dimensional objects with self-supporting structures like bridges or overhanging parts due to the liquid material dripping after extrusion, limiting the angle of inclination for upward widening shapes, and requiring additional processing steps for supporting structure removal.
Innovation Solution
The method involves identifying cantilevered and overhanging parts in the pattern, locally cooling the extruded material around the extruder nozzle to solidify it before placement, and using a micro-fan to control cooling, ensuring the material connects properly with the underlying layer without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material is extruded in liquid state from extruder, then material can be easily deposited and shaped, but liquid material drips down and cannot form self-supporting structures
Solution Approach 1:
The patent applies preliminary cooling action to the extruded material immediately after deposition. A cooling device cools the extruded material before it fully solidifies, creating a self-supporting structure that can maintain overhanging and cantilevered geometries without dripping or deforming under gravity.
Solution Approach 2:
The patent changes the temperature parameter of the extruded material by applying local cooling. This temperature reduction causes the material to solidify faster and maintain its shaped form, enabling the creation of self-supporting structures with overhanging parts that would otherwise be impossible with liquid extruded material.
2Manufacturing precision
If local cooling is applied to extruded material, then material solidifies and maintains shape, but additional cooling equipment is required
Solution Approach 1:
The patent applies cooling locally only to the extruded material rather than cooling the entire build chamber or all material. This localized cooling approach achieves precise shape control for overhanging parts while minimizing the complexity and energy consumption of the cooling system.
Solution Approach 2:
The patent introduces a cooling device as an intermediary between the extruder and the build platform. This intermediary component enables shape control of extruded material without requiring complex modifications to the extruder itself or the entire 3D printing system.
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 allows for the reliable production of three-dimensional objects with self-supporting and overhanging parts using inexpensive 3D printers, preventing material deformation and the need for additional supporting structures, while maintaining the simplicity and cost-effectiveness of existing printers.
Implementation Method 1
during the extrusion of the material according to step c), the extruded material is cooled locally in the area around an extruder nozzle of the extruder and is thus solidified
Implementation Method 2
the material being extruded in a liquid state from an extruder and being solidified upon impact with a base plate or an underlying layer of material
Data Source
AI summary
The method involves extruding and solidifying a thermoplastic material (18) or an underlying material layer in a liquid state from an extruder (12). The used material is connected to the underlying material layer, and the used material is placed layer by layer in a predetermined pattern. The freely suspended and/or connected portions are determined. The areas in which the underlying layer material is placed in the pattern, are determined. The used material is extruded and cooled locally in a region of an extrusion die (14) of the extruder, and solidified. Independent claims are included for the following: (1) an apparatus for producing three-dimensional objects; and (2) a computer program for producing three-dimensional objects.