Hardened Extrusion Tip Insert for Abrasive Additive Manufacturing
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Solution Overview
Problem
Standard extrusion tips in additive manufacturing systems wear out quickly when printing with polymeric materials containing abrasive fillers like carbon fiber or glass fiber, leading to inaccurate extrusion and frequent replacement needs.
Innovation Solution
A hardened extrusion tip insert made of materials like tungsten carbide is press-fitted into the liquefier assembly, providing abrasion resistance and reducing wear, allowing for extended use without the need for additional fastening methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard extrusion tip is used with abrasive polymeric materials, then the system can print with high-performance materials, but the extrusion tip wears out quickly leading to inaccurate extrusion and frequent replacement
Solution Approach 1:
The patent applies composite materials by combining a metal extrusion tip with a hardened insert made of wear-resistant material such as tungsten carbide or ceramic. This composite structure allows the extrusion tip to maintain the structural integrity and thermal conductivity of metal while incorporating the abrasion resistance of hardened materials, thereby enabling reliable printing with abrasive high-performance polymers without rapid wear
Solution Approach 2:
The patent applies local quality by implementing a hardened insert only at the critical extrusion port area where material contact occurs, rather than hardening the entire extrusion tip. This localized hardening provides wear resistance precisely where needed while maintaining the overall structural properties of the metal tip, solving the contradiction between versatility with abrasive materials and reliability of the extrusion tip
2Reliability
If a hardened insert is added to the extrusion tip, then wear resistance is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the extrusion tip into two functional segments: a metal body that provides structural support and thermal management, and a separate hardened insert that provides wear resistance. The insert is designed as a removable component that can be pressed into place, allowing the system to achieve enhanced reliability without permanently complicating the overall device structure
Solution Approach 2:
The patent applies the extraction principle by removing the wear-resistant function from the base metal material and incorporating it as a separate inserted component. This extracted hardened insert can be independently selected and replaced, simplifying the design process and allowing the metal extrusion tip to focus on providing structural integrity while the insert handles abrasion
3Manufacturing precision
If frequent extrusion tip replacement is performed, then accurate extrusion is maintained, but productivity decreases due to maintenance interruptions
Solution Approach 1:
The patent applies preliminary action by pre-installing the hardened insert into the extrusion tip during manufacturing or initial setup. This preliminary incorporation of the wear-resistant component ensures that the extrusion tip maintains its dimensional accuracy and extrusion precision throughout extended use, eliminating the need for frequent replacements and thereby maintaining high productivity without compromising manufacturing precision
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 hardened tip insert significantly extends the life of the extruder by reducing wear from abrasive materials, maintaining accurate extrusion and reducing maintenance needs, while allowing for the reliable printing of parts with high-performance materials.
Implementation Method 1
A hardened tip insert is inserted within the extrusion tip to reduce wear on the extrusion tip. The tip insert is constructed of a material that resists abrasion, such as, but not limited to, tungsten carbide or ceramic.
Implementation Method 2
A heater positioned about the liquefier tube proximate the second end, where the heater configured to heat feedstock material to a molten state.
Implementation Method 3
The extruded flow of material is deposited as a sequence of roads onto a substrate, where it fuses to previously deposited material and solidifies upon a drop in temperature.
Data Source
AI summary
A liquefier assembly for use in an extrusion-based additive manufacturing system includes a liquefier tube compositionally comprising a metallic material, and having a first end and a second end offset along a longitudinal axis, and a flow channel extending from the first end to the second end. The assembly further includes an extrusion tip compositionally comprising a metallic material and coupled to the second end of the liquefier tube, the extrusion tip having a cavity having an interior shoulder wherein the cavity terminates in an opening. The liquefier includes a hardened insert compositionally comprising a material that is harder than the metallic material of the extrusion tip and the metallic material of the liquefier tube. The hardened insert has an exterior shoulder that engages the interior shoulder of the extrusion tip such that the insert is press fit within the extrusion tip. The tip insert has a channel that aligns with the flow channel wherein the channel terminates at an extrusion port configured to extrude material therefrom.