Metal 3D Printer Wire Extrusion Induction Heating
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Solution Overview
Problem
Existing metal 3D printing technologies are costly, require expensive and hazardous metal powders, have long print times, and are limited to small-scale manufacturing due to high equipment costs and low print resolutions.
Innovation Solution
A metal 3D printer utilizing an induction heating system and a print head assembly with a crucible and nozzle for melting and depositing metal wire feedstock, along with a shielding gas system to prevent oxidation, allowing for efficient and precise deposition of molten metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder bed fusion or direct energy deposition is used, then metal 3D printing capability is achieved, but equipment cost increases to several hundred thousand or over a million dollars
Solution Approach 1:
The patent replaces complex laser-based melting systems with a simpler extrusion-based mechanical system. Instead of using high-power lasers to melt metal powder (powder bed fusion) or simultaneously deposit and fuse metal (direct energy deposition), the invention uses a extrusion mechanism that pushes molten metal through a nozzle to form layers. This substitution of the heating and deposition mechanism dramatically reduces equipment complexity and cost while maintaining metal 3D printing capability
Solution Approach 2:
The patent changes the fundamental parameters of the metal 3D printing process by switching from powder-based materials to wire-based materials, and from laser melting to extrusion deposition. This parameter change allows the use of simpler, less expensive equipment while achieving the same end result of creating metal parts through additive manufacturing
2Reliability
If metal powder is used as feedstock, then metal 3D printing is enabled, but material cost increases and handling becomes hazardous
Solution Approach 1:
The patent changes the physical form of the metal feedstock from fine powder to wire form. This parameter change eliminates the hazards associated with metal powder handling (respiratory issues, fire risks) while reducing material costs. Wire feedstock is safer to handle, less expensive, and can be fed through the extrusion system in a controlled manner
Solution Approach 2:
The patent uses wire feedstock that can be easily replaced and is less expensive than metal powder. The wire is consumed during the printing process and can be replenished from standard spools, making the material more economical and less hazardous compared to expensive, sensitive metal powders
3Reliability
If existing metal 3D printing techniques are used, then metal parts are manufactured, but print time increases
Solution Approach 1:
The patent replaces slow laser scanning and melting processes with a faster extrusion-based deposition system. The extrusion mechanism can continuously deposit molten metal at higher speeds compared to layer-by-layer laser processing, significantly reducing print time while maintaining manufacturing capability
Solution Approach 2:
The patent implements continuous extrusion of molten metal through the nozzle, allowing for uninterrupted deposition of material. This continuous action eliminates the stop-and-go nature of laser-based processes, maintaining steady printing speed and reducing overall print time through sustained productive operation
4Productivity
If printers are made large to increase manufacturing scale, then production capacity increases, but equipment cost and complexity increase
Solution Approach 1:
The patent creates a versatile extrusion-based metal 3D printer that can handle various wire materials and produce different part sizes without requiring specialized equipment. The same basic extrusion mechanism can be used for small prototypes or larger production parts, eliminating the need for multiple specialized machines and reducing overall system complexity
Data Source
AI summary
A metal 3D printer is disclosed for fabricating metal articles by depositing molten metal onto a print bed. The metal 3D printer has a print head formed of a crucible and a nozzle. The crucible heats the molten metal and the nozzle deposits the molten metal onto the print bed. The 3D printer further includes an induction heating system to heat the print head and a heated print bed disposed below the nozzle. The metal 3D printer also comprises a computer numerically controlled (CNC) gantry configured to move the print head and the print bed relative to each other along X, Y, and Z axes. A shielding gas blower may direct a first stream of shielding gas proximate to the crucible and a second stream of shielding gas proximate to the nozzle. The feedstock for the printer may comprise a plurality of wire strands braided together. A mesh overlay may be positioned on top of the print bed.