3D Printer Extruder Assembly with Rotating Shutter for Precision
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Solution Overview
Problem
Conventional three-dimensional object printers face a trade-off between build speed and resolution due to the size of the nozzle, where larger nozzles produce objects quickly but with reduced detail, and smaller nozzles produce more detailed objects but at slower speeds.
Innovation Solution
An extruder assembly with an extrusion slot and actuated shutter system that allows for precise control over the extrusion of build material, enabling faster and more detailed three-dimensional object printing by translating and rotating the extruder body while adjusting the extrusion slot's width to optimize filament width and printing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a larger diameter nozzle is used, then build speed is improved, but build resolution deteriorates
Solution Approach 1:
The single nozzle is segmented into multiple nozzles arranged in an array, where each nozzle can be independently controlled. This allows the system to use multiple nozzles simultaneously to print different portions of the build object, effectively increasing build speed while maintaining the fine resolution capabilities of individual small nozzles.
Solution Approach 2:
The invention transitions from a single-point extrusion approach to a multi-point array approach, adding spatial dimensionality to the extrusion process. The nozzles are arranged in specific patterns (e.g., rectangular arrays, hexagonal arrays) that enable parallel extrusion across multiple locations, simultaneously improving productivity and maintaining precision.
2Manufacturing precision
If a smaller diameter nozzle is used, then build resolution is improved, but build speed deteriorates
Solution Approach 1:
The build object is divided into multiple regions, each served by a dedicated nozzle in the array. This segmentation allows small nozzles to maintain their high resolution capabilities while the collective action of multiple nozzles compensates for the reduced speed of individual nozzles, achieving both high resolution and improved overall build speed.
Solution Approach 2:
Multiple small nozzles are merged into a coordinated array system that functions as a unified extrusion platform. The combined output of multiple high-precision nozzles achieves the productivity of a single large nozzle while maintaining the superior resolution characteristics of smaller nozzles.
Data Source
AI summary
A method of operating an extruder assembly in a three-dimensional object printer translates and rotates an extruder body having an extrusion slot to produce three-dimensional objects more quickly and with greater precision. The method also includes rotating and moving one or more shutter bodies with respect to the extrusion slot to form a continuous filament of material of various sizes and shapes.