Granule-Fed 3D Printer Printhead With Integrated Melting
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Solution Overview
Problem
Existing 3D printer printheads using thermoplastic filaments are expensive and prone to wear, while those using granules face issues with complex melting geometries and increased wear on the cylinder wall, leading to inefficiencies and high maintenance costs.
Innovation Solution
A compact printhead design using a hydraulic or electric actuating device, a supply device for granules, a flange with a cooling device, and a nozzle head with heating elements, incorporating a pocket piece and separate piston bushing to manage thermal and mechanical stresses, ensuring efficient material conversion and reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If granules are used as starting material with auger conveyance, then material cost is reduced and mixing capability is improved, but device complexity and footprint increase
Solution Approach 1:
The invention extracts the melting function from a separate auger-based system and integrates it directly into the printhead. The granules are fed directly into the printhead where they melt in a controlled zone, eliminating the need for complex external auger conveyance and mixing systems while maintaining the benefits of granule usage.
Solution Approach 2:
The invention merges the material feeding, melting, and dispensing functions into a single integrated printhead unit. The granule feed channel, melting zone with heating element, and nozzle are combined in one compact structure, simplifying the overall system while enabling granule-based printing.
2Productivity
If piston force is increased to improve material discharge, then printing speed is improved, but wear on cylinder wall increases
Solution Approach 1:
The invention employs a disposable or easily replaceable liner inside the cylinder that contacts the granules and melt. This liner can be replaced without replacing the entire cylinder, allowing high-force piston operation while the liner absorbs the wear. The liner acts as a sacrificial component that protects the expensive cylinder structure.
Solution Approach 2:
The invention changes the friction parameters by introducing a low-friction coating or material for the cylinder liner. This allows the piston to exert high forces for fast printing while the reduced friction minimizes wear on the cylinder wall, decoupling the relationship between force and wear.
3Productivity
If heating power is increased to improve melting speed, then printing speed is improved, but energy consumption increases
Solution Approach 1:
The invention concentrates heating power locally in the melting zone where granules are transformed to liquid, rather than heating the entire printhead uniformly. The heating element is positioned to directly contact or closely approach the granule bed, creating a high heat flux zone that melts material quickly with minimal overall energy consumption.
Solution Approach 2:
The invention performs preliminary heating of the printhead and melting zone before granule feeding begins. This pre-heating reduces the thermal mass that needs to be heated during operation, allowing faster melting with lower sustained power consumption. The system maintains optimal melting temperature with minimal energy input after the initial heating phase.
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
The design allows for high dynamics and stable printing processes with reduced wear, lower costs, and improved material mixing, enabling faster and more precise 3D printing with granules, particularly at high speeds.
Implementation Method 1
nozzle head (6) with heating elements (61, 63) in order to convert the material (10) from a solid phase (10), via a plastic phase (11) to a liquid phase (12)
Implementation Method 2
convert the material from a solid phase, via a plastic phase to a liquid phase
Implementation Method 3
flange (5) which comprises a cooling device (50)
Data Source
AI summary
The invention relates to a printhead (100) for a 3D printer, comprisingan actuating device (110) arranged in a housing (1) of the printhead (100) for actuating a piston (3), a supply device (2) for a printable material (10), a flange (5) with a cooling device (50), said flange being arranged at the housing (1) and the supply device (2), a nozzle head (6) with heating elements (61, 63) for converting the material (10) from a solid phase (10) into a liquid phase (12) and a nozzle (8) for discharging the liquid phase (12) of the material (10) out of the nozzle head (6).According to the invention, a pocket piece (7) is arranged inside the nozzle head (6).