Movable Inner Nozzle for Variable 3D Printer Extrusion
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Solution Overview
Problem
3D printing technologies face a conflict between achieving quick material throughput for large areas and precision for filigree outer contours due to fixed nozzle diameters, limiting the range of materials that can be used, especially those with fibers or particles that may clog small nozzles.
Innovation Solution
An extruder design featuring a linearly movable inner nozzle within an outer nozzle, allowing for variable effective cross-sections and pressure control, enabling the use of a wide range of materials by switching between small and large outlet openings, and using a conveying screw to exert pressure closer to the nozzle outlet for consistent material application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large nozzle diameter is used, then material throughput speed is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent implements a movable inner nozzle that can be positioned at different locations within the outer nozzle. By moving the inner nozzle between a retracted position (for large effective diameter and high throughput) and an extended position (for small effective diameter and high precision), the system dynamically adapts the nozzle characteristics to match the current printing requirements, resolving the contradiction between speed and precision.
Solution Approach 2:
The nozzle is divided into two functional parts: an outer nozzle and an inner nozzle. The inner nozzle can be independently moved within the outer nozzle, creating separate functional zones. This segmentation allows the system to switch between using the large outer nozzle opening for fast material deposition and the small inner nozzle opening for precise contour work, eliminating the need to choose a fixed diameter.
2Manufacturing precision
If a small nozzle diameter is used, then manufacturing precision is improved, but material throughput speed deteriorates
Solution Approach 1:
The movable inner nozzle enables dynamic switching between precision mode (inner nozzle extended, small effective diameter) and throughput mode (inner nozzle retracted, large effective diameter). This dynamic adaptation allows the system to optimize for precision when printing filigree contours while maintaining high throughput capability when filling large areas.
Solution Approach 2:
The combined nozzle system serves multiple functions: it can print both large-area fills and fine contours using a single nozzle assembly. The inner nozzle's mobility allows the same physical structure to function as both a large-diameter nozzle for speed and a small-diameter nozzle for precision, eliminating the need for multiple specialized nozzles.
3Device complexity
If a fixed nozzle diameter is used, then device complexity is reduced, but adaptability deteriorates
Solution Approach 1:
By adding the mobility capability to the inner nozzle, the system transforms from a fixed, simple structure to a dynamic, adaptive structure. The movement mechanism allows the nozzle to adjust its effective diameter based on printing requirements, significantly increasing versatility while adding only moderate complexity through the linear actuator and control system.
Solution Approach 2:
The inner nozzle is nested within the outer nozzle, creating a compact multi-functional structure. This nesting arrangement allows the system to achieve adaptability through the positionable inner nozzle while maintaining a relatively simple overall structure, as the inner nozzle utilizes the space already defined by the outer nozzle rather than requiring separate mounting structures.
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 design allows for precise control of material flow, prevents clogging issues with fibrous materials, and enables the use of diverse materials like glass or carbon fiber-reinforced polymers, while maintaining uniform pressure and efficient material application, independent of material properties.
Implementation Method 1
the feeding of the starting material via the conveying screw has the effect that, in the interior space of the outer nozzle, a controllable pressure is constantly built up and the application of material is thus realized in a uniform manner
Implementation Method 2
If the inner nozzle is moved into the vicinity of the outlet opening of the outer nozzle, said inner nozzle completely or partially blocks this outlet opening
Data Source
AI summary
Extruder (1) for a 3D printer, comprising at least one outer nozzle (2) and a conveying worm (3) for feeding liquid and/or plasticized starting material (4) into the interior chamber (21) of the outer nozzle (2), wherein an inner nozzle (5) is arranged in the interior chamber (21) of the outer nozzle (2), wherein the interior chamber (51) of the inner nozzle (5) is connected to the interior chamber (21) of the outer nozzle (2) via at least one duct (52, 52a, 52b) which is continuous for the starting material (4), and wherein the inner nozzle (5) is mounted such that it can be moved linearly along the longitudinal axis (2a) of the outer nozzle (2). A 3D printer (100) having the extruder (1) and means (8) for generating a relative movement between the extruder (1) and a construction surface (101), on which the object (102) to be manufactured is produced.