Micro-Roller Compressing Fused Deposition for Metal 3D Printing
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Solution Overview
Problem
Dieless fused deposition modeling methods face issues such as material flowing, dropping, crumbling, cracking, deformation, and unstable performance due to gravity, rapid heating, and rapid cooling, affecting the accuracy and quality of manufactured parts and molds.
Innovation Solution
A method involving slicing a 3D CAD model, generating numerical control codes, and using a micro-roller or micro-extrusion unit with a welding gun or laser beam to perform fused deposition modeling, synchronously compressing and processing the material to prevent material flow and enhance accuracy, while adjusting pitch and angle to support complex shapes, and applying plastic deformation to reduce tensile strength and prevent cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dieless fused deposition modeling is used to manufacture metal parts, then production flexibility and complexity handling are improved, but material flowing, dropping, and crumbling occur due to gravity
Solution Approach 1:
The patent applies anti-gravity support structures (temporary supports and counter-weight mechanisms) to counteract the gravitational force acting on molten material during deposition. This prevents material flowing and dropping in complex geometries while maintaining the flexibility to manufacture intricate parts that would otherwise be impossible to produce with traditional methods.
Solution Approach 2:
The patent introduces intermediary elements such as temporary support structures and control layers between the molten material and the build platform. These intermediaries provide mechanical support during the deposition process, preventing material crumbling and maintaining dimensional accuracy for complex geometries without compromising the final part quality.
2Productivity
If rapid heating and rapid cooling are applied during fused deposition modeling, then productivity is improved, but cracking, deformation, and large residual stress occur
Solution Approach 1:
The patent employs periodic heating and cooling cycles with controlled rates instead of continuous rapid thermal changes. By using periodic action with optimized timing and temperature gradients, the system maintains high productivity while allowing sufficient time for stress relaxation, thereby preventing cracking and deformation in the deposited material.
Solution Approach 2:
The patent dynamically adjusts thermal parameters (heating rate, cooling rate, temperature gradients) during the deposition process based on the specific geometric features being manufactured. This parameter optimization allows rapid deposition when possible while preventing thermal stress accumulation that leads to cracking and deformation.
3Manufacturing precision
If support structures are added to prevent material flowing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the support structure system into segmented, modular components that can be selectively placed only where needed during deposition. This segmentation reduces overall support complexity while maintaining precision, as supports are distributed in discrete locations rather than forming continuous complex structures.
Solution Approach 2:
The patent applies support structures with local quality optimization, providing enhanced support only in specific regions where material flowing is most likely to occur based on geometric analysis. This localized approach maintains manufacturing precision in critical areas while minimizing overall device complexity and support material usage.
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 improves the accuracy, surface quality, and formability of parts and molds by preventing material flow and deformation, reducing the need for extensive finishing processes and achieving high-quality, low-cost production of metal, intermetallic, ceramic, and composite materials.
Implementation Method 1
performing fused deposition modeling of powders or wire material of metal, intermetallic compounds, ceramic and composite functional gradient materials by layer using a welding gun on a substrate layer via a numerical control gas shielded welding beam or laser beam
Implementation Method 2
the micro-roller or the micro-extrusion unit synchronously moves along with fused deposition area whereby compressing and processing the fused deposition area during the fused deposition modeling
Implementation Method 3
Through applying plastic deformation on this area, the accuracy and surface smoothness of the fused deposition layer are improved, the additional tensile strength of the weld bead and its adjacent area are reduced, and the deformation and cracks
Data Source
AI summary
A method for manufacturing parts and molds by: 1) slicing a three-dimensional CAD model of a part or mold; 2) planning a modeling path according to slicing data of the three-dimensional CAD model, whereby generating numerical control codes for modeling processing; and 3) performing fused deposition modeling of powders or wire material of metal, intermetallic compounds, ceramic and composite functional gradient materials by layer using a welding gun on a substrate layer via a numerical control gas shielded welding beam or laser beam according to a track specified by the numerical control code for each layer. A micro-roller or a micro-extrusion unit is installed at a contact area between melted and softened areas. The micro-roller or the micro-extrusion unit synchronously moves along with fused deposition area, which results in compressing and processing of the fused deposition area during the fused deposition modeling.