Large-Part Thermoplastic 3D Printing With Integrated Trimming
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Solution Overview
Problem
Existing 3D printing methods for thermoplastic parts are slow and require heated environments, leading to internal stresses, separate machines for printing and trimming, and difficulties in handling large parts due to size and weight, as well as inaccuracies in alignment and cooling processes.
Innovation Solution
A machine that prints at ambient temperature using a larger print bead, allowing natural cooling of each layer, integrates printing and trimming on the same machine, and uses a high-wall design with dust and fume extraction, enabling continuous printing and reducing the need for separate machines and handling large parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heated environment and table are used to maintain bonding temperature, then material adhesion is improved, but internal stresses and warping increase
Solution Approach 1:
The patent removes the heated table and heated environment from the printing system, extracting the harmful thermal maintenance mechanism while preserving the essential bonding function through ambient temperature operation and rapid sequential printing
Solution Approach 2:
The patent applies preliminary cooling to the printed part between layers, allowing each layer to cool and stabilize before the next is applied, preventing cumulative thermal stress and warping while maintaining adhesion through controlled temperature gradients
2Manufacturing precision
If thin filament and thin print layers are used to generate smooth surface, then surface quality is improved, but manufacturing speed decreases
Solution Approach 1:
The patent changes the material delivery parameters from thin filament to thick paste or putty-like material, and changes the layer thickness parameters accordingly, enabling rapid deposition of thick layers that are then machined to final dimensions, achieving both high speed and smooth surface finish
Solution Approach 2:
The patent segments the manufacturing process into two distinct stages: rapid near-net-shape printing using thick material layers, followed by separate machining operations to achieve final surface quality and dimensions, allowing each stage to optimize for its specific goal
3Ease of manufacture
If separate machines are used for printing and trimming, then functional specialization is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines the printing and trimming functions into a single integrated machine system, where the printing apparatus includes integrated machining capabilities, eliminating the need for separate machines and reducing overall system complexity and space requirements
Solution Approach 2:
The patent designs the printing machine to perform multiple functions: additive printing of near-net-shape parts, machining of excess material, and finishing operations, making the machine universal and eliminating the need for multiple specialized machines
4Volume of moving object
If large parts are printed using traditional methods, then part size capability is improved, but handling and alignment difficulties increase due to weight and size
Solution Approach 1:
The patent applies preliminary machining and finishing operations within the same machine system before part removal, completing all necessary operations while the part is still secured in the printing apparatus, eliminating the need to handle and reposition large, heavy parts
Solution Approach 2:
The patent combines printing and machining operations in a single integrated system, allowing large parts to be printed and then immediately machined to final dimensions without requiring external handling or repositioning, reducing operational difficulty despite large part size
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
Facilitates faster and more efficient production of large thermoplastic parts with reduced internal stresses and improved alignment, while minimizing space requirements and operational complexity.
Implementation Method 1
melting a thin layer of thermoplastic material, and applying this material in layers
Implementation Method 2
a table, which when heated sufficiently, was used to bond to the material being printed and secure the material in place
Implementation Method 3
the print environment may require heat to maintain a minimum part temperature so that the newly printed material may adhere properly
Data Source
AI summary
Embodiments of the present disclosure are drawn to additive manufacturing apparatus and methods. An exemplary additive manufacturing system may include an extruder, the extruder having an opening dimensioned to receive a material. The apparatus may also include an extruder output in fluid communication with the extruder, wherein the extruder output extends away from the extruder along a longitudinal axis. One or more heaters positioned along at least a portion of the extruder output may also be included, and, as the material passes through the extruder output, the one or more heaters may at least partially melt the material. The system may also include a gear pump in fluid communication with the extruder output for receiving the at least partially melted material, and a nozzle in fluid communication with the gear pump for depositing the at least partially melted material.