Metal Alloy 3D Printer Inert Chamber Thermal Control

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Solution Overview

Problem

Traditional 3D printers face issues with firm attachment and deformation of 3D laminates due to temperature differences between the filaments and the floor plate, resulting from the cooling contraction of metal alloy filaments piled layer upon layer in open spaces.

Innovation Solution

A 3D printer design featuring a chamber heated to match the nozzle temperature, using a high frequency induction heating coil to melt and extrude metal alloy filaments, with a controlled environment to minimize oxidation and deformation by maintaining consistent temperature and using a pipe shape nozzle body with a sliding mechanism for precise layering on a floor plate within the chamber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If metal alloy filament is melted and extruded in a nozzle heated in open spaces, then the printing process can be completed, but severe deformation occurs due to contraction from cooling of the 3D laminate

Engineering Contradiction:

Improveprinting process completionVSAvoiddeformation of 3D laminate

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent introduces an inert gas atmosphere (argon or nitrogen) within the printing chamber to replace the open space environment. This inert atmosphere prevents oxidation of the metal alloy filament during melting and extrusion, while also maintaining a controlled thermal environment that reduces temperature fluctuations and minimizes thermal contraction deformation of the printed laminate.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent controls and maintains the temperature parameters within the printing chamber to match the nozzle temperature, creating a thermal environment that minimizes temperature differential. This parameter control prevents excessive cooling and contraction of the metal alloy laminate during the printing process, thereby reducing deformation.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If metal alloy filament is piled up layer upon layer on a floor plate in open spaces, then the 3D laminate can be formed, but firm attachment between the laminate and filaments is compromised due to big differences in temperature

Engineering Contradiction:

Improve3D laminate formationVSAvoidattachment between laminate and filaments

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The inert gas atmosphere maintains a stable thermal environment around the floor plate and extruded filament, preventing rapid cooling and temperature differential. This stable thermal condition ensures proper bonding and firm attachment between layers as the metal alloy filament is deposited on the floor plate.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent maintains the floor plate temperature close to the nozzle temperature by controlling the chamber environment. This temperature parameter control ensures that the metal alloy filament remains at an appropriate temperature during deposition, enabling firm attachment between layers without premature cooling and bonding defects.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If metal alloy filament is extruded in open spaces, then the printing process can proceed, but oxidation of the 3D metal alloy laminate occurs

Engineering Contradiction:

Improveprinting process continuityVSAvoidoxidation of 3D metal alloy laminate

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the open space oxygen-containing environment with an inert gas atmosphere (argon or nitrogen) within the printing chamber. This inert environment prevents oxidation of the hot metal alloy filament during extrusion and protects the finished 3D metal alloy laminate from oxidation, while allowing the printing process to continue uninterrupted.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 ensures firm attachment and minimal deformation of the 3D laminate by maintaining consistent temperature and preventing oxidation, resulting in a stable and well-attached metal alloy structure.

Implementation Method 1

a nozzle heated by a high frequency induction heating coil

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

chamber heated to temperature similar to that of the nozzle so as to enhance mutual attachment and minimize deformation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

heated to prevent the oxidation of the 3D metal alloy laminate

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS11014150B23D printer for metal alloy filament

Publication Date: 2021.05.25 CHO KYUNGIL

AI summary

A 3D printer for a metal alloy filament is provided in which, in order to prevent the oxidation of a metal alloy laminate, an inert gas is introduced, the outside and heat and air are blocked, and a metal alloy filament that is melted in a nozzle and extruded is laminated one layer at a time on a floor plate installed inside a heated chamber and moving three-dimensionally with respect to the nozzle, in order to firmly attach the filament having little deformation.