Graphite Orifice Cleaning Tool for 3D Metal Printers
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Solution Overview
Problem
Current 3D metal object printers face challenges in cleaning nozzles and orifices due to high temperatures, which prevents the removal of bonded metal drops without shutting down and reinitializing the printer, leading to significant operational downtime and potential damage to the nozzle and orifice.
Innovation Solution
A method and tool for cleaning bonded metal drops from the nozzle and orifice using a high-temperature resistant orifice cleaning tool, such as one made of graphite, that can be used while the printer is operational, allowing for removal of adhered metal drops without complete initialization, utilizing an articulated arm to move the cleaning tool across the orifice and surrounding baseplate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cleaning methods (purge and flexible blade) are used, then ink drop satellites are removed, but the method cannot be applied to high-temperature metal drop printing and requires complete shutdown and reinitialization
Solution Approach 1:
The patent changes the material parameter of the cleaning tool to withstand high temperatures. The orifice cleaning tool is made of a high-temperature resistant material that can operate in the molten metal environment without deforming or degrading, enabling cleaning during ongoing operations without shutdown
Solution Approach 2:
The patent replaces the flexible blade mechanical cleaning system with a rigid orifice cleaning tool that can be precisely positioned and moved across the orifice by an articulated arm, enabling effective cleaning of bonded metal drops without requiring complete system shutdown
2Ease of manufacture
If the printer is shut down for cleaning, then metal drops can be removed from the nozzle and orifice, but significant operational time is lost and the printer must be reinitialized
Solution Approach 1:
The patent enables the cleaning function to be performed during normal operation without requiring external intervention or shutdown. The orifice cleaning tool is integrated into the operational system, allowing the printer to clean itself continuously during metal object formation
Solution Approach 2:
The patent positions the orifice cleaning tool and articulated arm in advance within the printer structure, ready to access and clean the orifice at any time during operation. The tool is pre-configured to move into position and perform cleaning before contamination significantly impacts drop formation
3Ease of operation
If elastomer or rubber materials are used for cleaning tools, then intimate contact with the faceplate is achieved, but these materials cannot endure high temperatures of 400°C and higher
Solution Approach 1:
The patent uses a high-temperature resistant material for the orifice cleaning tool that can withstand the extreme thermal environment of molten metal printing while maintaining the mechanical properties needed for effective cleaning contact with the orifice and surrounding baseplate
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
Enables the removal of bonded metal drops during ongoing operations, reducing downtime and preventing damage to the nozzle and orifice, maintaining consistent metal drop formation and trajectory without requiring printer shutdown or disassembly.
Implementation Method 1
An electrical current is passed through the coil to produce an electromagnetic field that causes the meniscus of the melted metal at a nozzle of the receptacle to separate from the melted metal within the receptacle and be propelled from the nozzle
Data Source
AI summary
A three-dimensional (3D) metal object manufacturing apparatus is equipped with an orifice cleaning system that removes metal drops that have adhered to a plate, an orifice in the plate, and a nozzle ejecting melted metal drops through the orifice during object forming operations. The orifice cleaning system includes an orifice cleaning tool that consists essentially of a soft carbon material, such as graphite. The orifice cleaning tool is configured with a handle that is gripped by an articulated arm to move the orifice cleaning tool against the plate, the orifice, and a portion of the nozzle at the orifice.