Fiber Feed Device for 3D Printing with Rotational Orientation Control
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Solution Overview
Problem
Existing methods for producing three-dimensional parts using solidifiable materials, such as thermoplastic materials, often fail to achieve desired material properties due to inadequate fiber reinforcement, particularly when producing small batches or prototypes, as they require high pressures and temperatures, which can lead to insufficient adhesion and fiber orientation challenges.
Innovation Solution
A device with a fiber feed system mounted on the discharge unit, allowing for rotational movement and precise orientation of fiber elements relative to the discharge unit, enabling targeted embedding of fibers within the solidifiable material during additive manufacturing, thereby enhancing material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high pressure and high temperature are used to discharge solidifiable material in small drop sizes, then adhesion strength is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent changes the physical parameters of material discharge by using a syringe pump to control the extrusion process, enabling precise control of drop size and discharge rate without requiring extreme pressures and temperatures. This alternative parameter control method achieves adequate adhesion while simplifying the overall device requirements.
Solution Approach 2:
The syringe pump acts as an intermediary device between the material reservoir and the discharge point, mediating the material flow to achieve controlled drop formation. This intermediary mechanism enables precise material delivery without directly applying high pressure at the discharge point, thereby reducing device complexity while maintaining adhesion strength.
2Adaptability or versatility
If fibers are fed separately from the material discharge unit, then fiber orientation flexibility is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent merges the fiber feed device with the material discharge unit by mounting the fiber feed device on the discharge unit. This integration ensures that fibers and material are deposited simultaneously at the same location, maintaining manufacturing precision while the separate mounting allows fiber orientation flexibility through independent positioning.
Solution Approach 2:
The fiber feed device is mounted on the discharge unit with rotational freedom, adding a rotational dimension to the fiber feeding mechanism. This enables fiber orientation control in multiple directions while maintaining precise co-deposition with the material, resolving the contradiction between flexibility and precision.
3Manufacturing precision
If fibers are fed through the outlet of the material discharge unit, then manufacturing precision is improved, but fiber orientation flexibility deteriorates
Solution Approach 1:
The fiber feed device is designed with dynamic mounting that allows rotational movement relative to the discharge unit. This dynamic configuration enables the fiber feed direction to be adjusted independently while maintaining precise alignment during deposition, achieving both manufacturing precision and orientation flexibility.
4Manufacturing precision
If separate fiber feed device mounted on discharge unit is used, then fiber orientation control is improved, but device complexity increases
Solution Approach 1:
The discharge unit is designed with multi-functionality by integrating the fiber feed device mounting capability into its structure. This universal design allows the discharge unit to simultaneously perform material discharge and support fiber feeding with orientation control, reducing overall device complexity while maintaining precision.
Data Source
AI summary
A device and a method for producing a three-dimensional object from at least one fluid-phase, fusable material has at least one discharge unit (12) with at least one outlet opening for the generative discharge of the fusable material for building up the object (50). By means of at least one fibre feeding device (60), at least one fibre element (61) is supplied for embedding the fibre element in the fusable material discharged from the discharge unit (12), wherein the fibre feeding device (60) is movable for the alignment of the fibre element in relation to an advancement in the building of the object. The fact that the fibre feeding device (60) is mounted on the discharge unit (12) and is movable in relation to the discharge unit (12) means that a selective introduction of fibre elements is made available for the production of a three-dimensional object with improved material properties by the generative process.