3D Printer Extruder Valve Timing for Layer Quality
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Solution Overview
Problem
In three-dimensional (3D) object printing, multi-nozzle extruders face challenges in accurately managing thermoplastic material flow due to issues with valve operation, leading to inconsistencies in material distribution on the faceplate, which affects the formation and quality of printed objects.
Innovation Solution
A method and system for operating a multi-nozzle extruder that involves identifying the required material flow for swath formation, closing all valves, lifting the extruder to an offset transition region start position, and then opening specific valves to establish an adequate material volume between the faceplate and the object being formed, ensuring accurate material distribution before reaching the start position for swath formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the extruder is lifted to avoid wiping material from the faceplate onto previously printed layers, then material contamination is prevented, but the amount of material on the faceplate cannot be accurately known
Solution Approach 1:
The system performs preliminary extrusion action at a transition region start position before reaching the actual swath start position. This preliminary action establishes the required material volume between the faceplate and the object being formed, ensuring accurate material distribution is achieved in advance, allowing the extruder to then be lifted without compromising measurement accuracy
2Ease of operation
If valves are operated to control thermoplastic material flow through nozzles, then material flow is controlled, but material distribution accuracy on the faceplate deteriorates
Solution Approach 1:
The system opens valves and establishes material flow at a transition region start position that is offset from the final swath start position. This preliminary positioning allows the material to be extruded and distributed accurately on the faceplate before the extruder reaches its final position, separating the valve operation from the precise material distribution point
Solution Approach 2:
The transition region start position acts as an intermediary location between the valve operation point and the final swath formation point. By establishing material flow at this intermediate position, the system mediates between the need for valve control and the requirement for precise material distribution on the faceplate
3Productivity
If the extruder moves directly to the start position for swath formation, then productivity is improved, but adequate material volume cannot be established between the faceplate and the object
Solution Approach 1:
The system performs preliminary material extrusion at a transition region start position offset from the final swath start position. This advance action ensures adequate material volume is established between the faceplate and the object being formed before the extruder reaches the final position, preventing material deficiency while maintaining efficient overall operation
Solution Approach 2:
The system introduces a temporal dimension to the extrusion process by separating the material establishment phase from the swath formation phase. By offsetting the transition region start position from the final start position, the system creates a time sequence where material volume is established first, then swath formation occurs, ensuring both adequate material quantity and high productivity
Data Source
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AI summary
An additive manufacturing system opens the valves in an extruder needed to form a swath and operates an actuator to move the extruder through a transition region with those valves open to establish an amount of extrusion material between a faceplate of the extruder and a portion of an object being formed that is adequate for formation of a swath. The length of the transition region is determined with reference to a viscosity of the material being extruded and a speed at which the extruder is moved to form the swath. The transition region can be perpendicular to a path of the extruder to form the swath or aligned with the path of the extruder to form the swath.