Light-Guiding Printer Nozzle for Local Filament and Substrate Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional 3D printing technologies face challenges in achieving high-speed and high-quality large-scale printing due to mechanical pin alignment issues and inefficient filament extrusion, leading to prolonged printing times and reduced productivity.
Innovation Solution
A novel nozzle structure featuring a light-guiding body that surrounds the filament, using light to continuously heat and melt the filament and preheat the substrate, optimizing filament discharge and bonding without the need for preheating the entire print surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If mechanical pins are used to bridge large diameters for large scale printing, then the printing scale can be increased, but the pins bend due to insufficient rigidity under the weight of the print-head system
Solution Approach 1:
The patent replaces the mechanical pin support system with a light-based heating system. The print-head is equipped with light sources (e.g., LEDs) that emit light through the nozzle to preheat the printing surface and melt the filament, eliminating the need for heavy mechanical pins to support and align the print-head over large distances. This substitution of mechanical support with optical functionality resolves the contradiction by enabling large-scale printing without compromising alignment stability.
2Reliability
If rigid mechanical pins are used to maintain alignment, then the alignment stability is improved, but the mass of the pins becomes prohibitively high
Solution Approach 1:
The patent eliminates the need for heavy rigid mechanical pins by substituting their alignment and support function with a lightweight print-head equipped with integrated light sources. The light-based system provides both the heating function and the positioning function, allowing the print-head to be much lighter while maintaining alignment stability through precise optical control rather than mechanical rigidity.
3Manufacturing precision
If the entire printing surface is preheated to improve bonding, then the bonding quality is improved, but the energy consumption and printing time increase significantly
Solution Approach 1:
The patent implements local preheating by directing light through the nozzle to heat only the specific area of the printing surface where filament deposition is occurring. This localized approach, rather than heating the entire printing surface, maintains high bonding quality at the deposition point while minimizing energy consumption and avoiding delays associated with heating large areas, thus preserving printing speed.
Solution Approach 2:
The patent applies preliminary heating action by preheating the printing surface locally at the nozzle exit point before filament deposition occurs. This preliminary local heating ensures optimal bonding conditions are already in place when the filament is deposited, improving bonding quality without requiring extended preheating of the entire surface, thereby maintaining high printing productivity.
4Ease of manufacture
If conventional heating methods are used to melt the filament, then the filament extrusion is achieved, but the print-head mass increases and movement speed decreases
Solution Approach 1:
The patent replaces conventional thermal heating systems (which require heavy heating elements, thermostats, and insulation) with a light-based heating system. The light sources (e.g., LEDs) integrated into the nozzle provide the necessary heat to melt the filament through optical energy, significantly reducing the print-head mass. This lighter print-head can then move faster while still achieving effective filament extrusion through the light-induced melting process.
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 configuration enhances printing speed and quality by reducing the print-head mass, allowing for faster and more precise movement, and improves filament extrusion and substrate cohesion, making large-scale printing more feasible with conventional-sized printers.
Implementation Method 1
guiding input light beam(s), properly entering the light guiding body, at its proximate portion and/or in one or more intermediate regions along the light guiding body, to propagate in a general propagation direction
Implementation Method 2
causing the propagating light beam(s) to interact with successive regions of the inner cavity (i.e., successive regions of the filament)... continuously heating of the filament along its length... towards the melting state
Implementation Method 3
the distal tip portion of the tubular member has a cross-sectional geometry different from that of the elongated tube portion to affect light reflections from the inner surfaces of the tubular member and allow the trapped light to escape through the distal part of the tubular member towards the printing plane, thereby causing local heating of the printing plane facing the distal part
Data Source
AI summary
A nozzle structure for discharging printing material onto a substrate is presented. The nozzle structure comprises a tubular member having a distal part that faces the printing plane when in operation and defining an elongated inner cavity along the tubular member for placement a filament printing material. The tubular member comprises light input ports on the proximal part thereof for directing light toward inner surfaces thereof. The tubular member has an elongated tube portion and a distal tip portion at the distal part thereof, configured and operable as a light guide trapping and guiding the input light along the tubular member in a general direction toward the distal part, thereby continuously transferring light field to distal regions of the elongated inner cavity. The distal tip portion is configured to allow the trapped light to escape towards the printing plane, thereby heating a location on the printing plane facing the nozzle.