3D Printing Hollow Cylindrical Bodies Outside-In
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Solution Overview
Problem
Existing methods for producing cylindrical parts with hollow interiors, such as rocket bodies and fuselages, are expensive, time-consuming, and generate significant waste, while also risking leaks and failure due to joints.
Innovation Solution
The method involves printing hollow bodies from the outside-in using a system that includes a rotatable print support base, a print head, and a guide rail, allowing for the deposition of extruded lines of print material to form continuous hollow portions around a rotational axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods (lathing, milling) are used to produce thin-walled cylindrical parts, then the parts can be manufactured with desired precision, but the manufacturing cost increases, manufacturing time increases, and material waste increases
Solution Approach 1:
The patent inverts the traditional manufacturing approach by printing from the outside surface inward rather than machining from the inside outward. The extrusion head deposits material layers that build up the cylindrical wall thickness from the exterior, eliminating the need for expensive and time-consuming machining operations while maintaining dimensional accuracy and reducing material waste
Solution Approach 2:
The patent replaces traditional mechanical machining processes (lathing, milling) with an additive manufacturing process. Instead of removing material through mechanical cutting tools, the system uses an extrusion head to deposit material in controlled layers, significantly reducing manufacturing time and cost while achieving the same precision requirements
2Shape
If separate parts are joined together to form cylindrical structures, then the desired shape can be achieved, but labor intensity increases, manufacturing cost increases, and reliability decreases due to potential leaks at joints
Solution Approach 1:
The patent merges the entire cylindrical structure into a single monolithic component manufactured in one continuous additive process. By building the cylinder wall as one integrated piece without separate segments or joints, the invention eliminates leakage risks at connection points while maintaining the desired cylindrical shape and reducing assembly labor
3Volume of moving object
If traditional manufacturing methods are used for large thin-walled structures, then the structures can be produced, but substantial material waste is generated
Solution Approach 1:
The patent inverts the material removal approach by using additive deposition from the outside inward. The extrusion head precisely deposits material only where needed to achieve the target wall thickness, eliminating the substantial material waste inherent in traditional subtractive machining of large thin-walled structures
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
This approach reduces manufacturing time and costs, minimizes waste, and enables the creation of hollow structures with smooth exterior surfaces and integrated internal structures, improving the reliability and efficiency of producing cylindrical parts.
Implementation Method 1
a print head (104) having a print nozzle (104N) oriented to dispense print media material (106). The print nozzle (104N) may be selectively controlled to dispense the print media material (106) in the form of extruded lines
Data Source
AI summary
Systems and methods for 3D printing hollow bodies, such as bodies having an exterior cylindrical shape with a hollow interior, are described. Such systems and methods utilize rotatable hollow print base supports having an interior size and/or shape that matches the desired exterior shape of the final printed structure. The printed bodies, methods, and systems enable printing of the desired hollow printed body from the outside-to-inside. They also allow easy production, customization, and modification of internal structures within the printed hollow body.