Metal 3D Printer with Integrated Processing Unit
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Solution Overview
Problem
Typical directed energy deposition (DED) type metal 3D printers require additional post-processing due to rapid solidification of molten metal, leading to degradation in work accuracy and efficiency.
Innovation Solution
A metal 3D printer design that integrates a processing unit and nozzle unit, allowing simultaneous movement in multiple axes, with a heating unit to maintain material temperature, and a table unit for supporting the material, enabling continuous manufacturing and processing without stopping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a typical DED type metal 3D printer injects molten metal through a nozzle, then material deposition is achieved, but the molten metal quickly solidifies causing degradation in work accuracy and work efficiency
Solution Approach 1:
The patent combines the manufacturing function (nozzle unit for material injection) and post-processing function (processing unit for cutting and polishing) into a single integrated system. The nozzle unit and processing unit are mounted on the same movable platform, allowing both operations to be performed sequentially on the sculpture without removing it from the device, thereby eliminating transfer time and improving both work accuracy and efficiency.
Solution Approach 2:
The processing unit performs post-processing operations (cutting, polishing) immediately after material deposition while the sculpture is still in position. The heating unit also applies heat treatment promptly after deposition to prevent rapid solidification and deformation, addressing the solidification issue before it causes accuracy degradation.
2Ease of manufacture
If the sculpture is transferred to a separate cutting device for post-processing, then material processing is completed, but work efficiency decreases due to transfer requirements
Solution Approach 1:
The patent integrates multiple processing capabilities (material injection, cutting, polishing, heating) into a single device. The nozzle unit, processing unit with cutting tool and polishing wheel, and heating unit are all mounted on the same system, allowing sequential operations without transferring the sculpture to separate devices, thereby maintaining processing capability while significantly improving work efficiency.
3Adaptability or versatility
If the nozzle unit and processing unit move independently, then operational flexibility is maintained, but collision risk increases
Solution Approach 1:
The patent mounts both the nozzle unit and processing unit on the same movable platform that can move along the X and Y axes. This coordinated movement ensures that both units move together in a synchronized manner, maintaining operational flexibility while eliminating the collision risk that would arise from independent movements of the two units.
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
Improves work accuracy and efficiency by preventing material cooling and allowing for simultaneous injection and processing, reducing the risk of collisions between the nozzle and processing units.
Implementation Method 1
a heating unit disposed on the fixed part to move in the third direction and disposed below the table unit to heat the table unit
Data Source
AI summary
A metal 3D printer includes a base unit including a fixed part, a first moving part disposed on the fixed part to move in a first direction, a second moving part disposed on the first moving part to move in a second direction, and a third moving part disposed on the second moving part to move in a third direction, a nozzle unit coupled to the second moving part to move in the first and second directions and move in the third direction and injecting a material for manufacturing a sculpture, a processing unit coupled to the third moving part to move in the first to third directions and processing the sculpture, a table unit disposed rotatably to the fixed part and disposed below the nozzle unit, and a heating unit disposed on the fixed part.