Layer Engagement Member for Reinforced Interlayer Connections in 3D Printing
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Solution Overview
Problem
Existing additive manufacturing methods for 3D printing, such as FDM, face challenges in achieving strong interlayer connections without requiring nozzle changes and increasing software complexity, especially when depositing non-planar layers.
Innovation Solution
A method involving a layer engagement member that locally fuses layers by moving downward and upward at specific x-y locations during the deposition process, allowing for reinforced interlayer connections without nozzle changes and maintaining manufacturing speed and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If non-planar layers are deposited to interconnect underlying layers, then interlayer connection strength is improved, but device complexity increases due to requiring different extruder nozzles
Solution Approach 1:
The extruder nozzle is designed to perform multiple functions: depositing material and creating interlayer connections through plunging motion. This multi-functionality eliminates the need for separate nozzles for different operations, reducing device complexity while maintaining strong interlayer connections.
Solution Approach 2:
The extruder nozzle executes dynamic plunging motion (downward and upward movement) during the deposition process. This dynamic action allows the same nozzle to both deposit material and create reinforced interlayer connections, avoiding the need for multiple static nozzle designs.
2Strength
If non-planar layers are deposited to interconnect underlying layers, then interlayer connection strength is improved, but software processing complexity increases
Solution Approach 1:
The software controls dynamic plunging motion of the extruder nozzle at specific locations during layer deposition. This dynamic approach allows planar layer deposition with localized reinforcement, keeping software processing relatively simple compared to full non-planar layer generation.
Solution Approach 2:
Instead of depositing non-planar layers throughout the entire structure, the invention applies localized plunging action at specific x-y locations where interlayer connection reinforcement is needed. This localized approach maintains software processing simplicity while achieving the desired strength improvement.
3Strength
If plunging motion is used to create reinforced interlayer connections, then interlayer bonding strength is improved, but manufacturing time increases
Solution Approach 1:
Instead of applying plunging motion throughout the entire deposition process, the invention applies it only partially at specific locations where interlayer connection reinforcement is needed. This partial action maintains manufacturing speed while providing targeted strength improvement.
Solution Approach 2:
The plunging motion is integrated into the continuous deposition process, allowing interlayer connection reinforcement to occur during normal manufacturing operations rather than requiring separate additional steps. This maintains manufacturing speed while improving interlayer bonding.
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 method effectively 'spot welds' layers, significantly enhancing interlayer bonding strength and durability without increasing software complexity or requiring nozzle changes, thus improving the overall strength and consistency of 3D objects.
Implementation Method 1
lowering the layer engagement member for engagement with the plurality of layers, wherein a pressing surface of the layer engagements member is lowered at least below an upper surface of a second most upper layer, thereby locally fusing an upper layer and the second most upper layer at the x-y location
Data Source
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AI summary
A method for providing reinforced interlayer connections during layered deposition modelling is provided. The method comprises the steps of a) depositing a plurality of layers (1, 2) of extrudable material with an extruder head (10) on a build plate extending in an x and y direction; b) positioning a layer engagement member (3)at an x-y location above the plurality of layers (1, 2) where interlayer connection between the plurality of layers (1, 2) is to be reinforced; c) lowering the layer engagement member(3) for engagement with the plurality of layers (1, 2) wherein a pressing surface (3a) of the layer engagements member (3) is lowered at least below an upper surface(2a) of a second most upper layer (2), thereby locally fusing an upper layer (1) and the second upper layer (2) at the x-y location; and d) raising the layer engagement member (3) from the plurality of layers (1, 2).