Gravity-Fed Bulk Ink System for Continuous 3D Printing
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Solution Overview
Problem
In Composite-Based Additive Manufacturing (CBAM), the continuous process is disrupted and becomes costly and time-consuming when inkjet heads run low on fluid, requiring manual intervention and complex pumping systems to refill ink reservoirs.
Innovation Solution
A gravity-fed bulk ink system using flexible Mylar bags with a self-sealing quick disconnect nozzle and a load cell to monitor ink levels, allowing for seamless fluid delivery and bag changes without interrupting the printing process or introducing air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual refilling of inkjet heads is performed, then the process can be completed with simple equipment, but the continuous manufacturing process is disrupted and becomes time-consuming
Solution Approach 1:
The system uses a gravity-fed bulk ink delivery system with flexible bags that automatically refill inkjet heads without manual intervention. The bags are equipped with self-sealing quick disconnect nozzles that automatically seal when disconnected, preventing air bubbles and spillage, thus maintaining continuous operation.
Solution Approach 2:
A gravity-fed delivery system with flexible ink bags serves as an intermediary between bulk ink storage and the inkjet heads. This intermediary system enables automatic refilling through gravity flow, eliminating the need for manual pouring and complex pumping systems while maintaining continuous manufacturing.
2Reliability
If complex pumping systems are used to deliver bulk ink, then ink can be delivered reliably, but the system complexity increases
Solution Approach 1:
The patent replaces complex mechanical pumping systems with a gravity-fed delivery system. The flexible ink bags utilize gravitational force to deliver bulk ink to the inkjet heads, eliminating the need for pumps, valves, and complex plumbing while maintaining reliable ink delivery.
Solution Approach 2:
The system changes the delivery mechanism from pressure-based (pumps) to gravity-based flow. By positioning the bulk ink bags above the inkjet heads and using gravity as the driving force, the system achieves simple and reliable ink delivery without mechanical complexity.
3Quantity of substance
If rigid bottles with complex plumbing are used for ink delivery, then ink can be stored in bulk, but the system becomes difficult to operate and maintain
Solution Approach 1:
The patent uses flexible Mylar bags instead of rigid bottles for bulk ink storage. These flexible bags can be easily hung, connected, and disconnected without requiring complex plumbing. The flexibility of the bags allows for simple handling and replacement while maintaining bulk storage capacity.
Solution Approach 2:
The bulk ink storage is divided into individual replaceable flexible bags. Each bag can be independently handled, connected, and disconnected, allowing for easy operation and maintenance. When one bag is depleted, it can be quickly replaced without affecting the entire system.
4Ease of manufacture
If manual pouring of bulk ink is performed, then refilling can be done with simple equipment, but air bubbles are introduced and fluid is lost
Solution Approach 1:
The self-sealing quick disconnect nozzle acts as an intermediary between the bulk ink bag and the inkjet head reservoir. This intermediary component enables automatic sealing upon disconnection, preventing air bubbles from entering the system and preventing ink spillage, thus eliminating fluid loss while maintaining simple operation.
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 system maintains a consistent ink supply, enabling continuous operation by allowing for easy and tool-free bag changes and air removal, ensuring uninterrupted printing and reducing manual intervention and fluid loss.
Implementation Method 1
providing a hook attached to a load cell constructed to hang a fluid bag; reading the load cell to determine weight of the bag
Implementation Method 2
Gravity fed fluid delivery without requiring pumps
Data Source
AI summary
A bulk ink bag system in a composite-based additive manufacturing process (CBAM) keeps the inkjet heads (cartridges) on printers filled to the proper level of fluid at all times while the process runs. The system includes gravity fed fluid delivery without requiring pumps; is simple to connect and disconnect to system plumbing; has the ability to change ink bags without interrupting the print job or introducing air bubbles into the ink supply; and has the ability to disconnect partially used bags and reconnect them later.