Multi-Diameter Wire Feeder for Low-Waste Metal 3D Printing
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Solution Overview
Problem
Existing 3D printing methods using metal powders are costly, hazardous, and inefficient due to the high waste and precision requirements of powder spreading, while metal wire feedstock offers a safer and more efficient alternative.
Innovation Solution
A system and method utilizing a wire feeder with driver rollers and grooves to direct metal wire from a spool to a print head, reducing stress on the wire and enabling precise deposition through electrical resistance heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If metal powder is used as feedstock for 3D printing, then the printing process can be performed, but material waste increases and handling becomes hazardous
Solution Approach 1:
The invention changes the physical form parameter of the feedstock from powder to wire. This parameter change fundamentally alters the material handling characteristics, eliminating dust generation and reducing waste while maintaining the ability to deposit material precisely for 3D printing applications
Solution Approach 2:
The wire feedstock is designed as a consumable element that is fed continuously through the printing process. Unlike powder that requires careful handling, storage, and cleanup, the wire can be simply replaced when depleted, reducing both waste handling hazards and operational complexity
2Productivity
If metal powder is spread across the entire build area for each layer, then complete coverage is achieved, but the process speed decreases
Solution Approach 1:
The invention extracts the feedstock delivery mechanism from the conventional powder spreading approach. Instead of spreading powder across the entire build area, the wire is selectively delivered only to the specific locations where material is needed, based on the digital model instructions. This extraction of the feedstock delivery function enables precise placement without the time-consuming step of covering the entire build area
Solution Approach 2:
The wire feedstock is pre-positioned and fed continuously to the deposition point before actual layer formation begins. This preliminary positioning of the feedstock delivery system allows immediate deposition at the correct location and thickness, eliminating the need for preliminary powder spreading across the entire build area
3Reliability
If driver rollers with grooves are used to direct wire, then stress on wire is reduced, but device complexity increases
Solution Approach 1:
The driver roller incorporates grooves with specific local geometries that match the wire diameter and properties. These localized groove features are designed to contact and guide the wire at specific points, distributing stress appropriately without requiring complex overall roller designs. Each groove is optimized for its specific function of guiding wire of particular dimensions
Solution Approach 2:
The grooves in the driver roller are designed with curved surfaces that match the cylindrical geometry of the wire. This curvature compatibility allows the wire to nestle into the grooves smoothly, reducing stress concentration points and preventing wire damage while maintaining a relatively simple roller structure
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
The system reduces material waste, minimizes handling risks, and enhances printing efficiency by using metal wire feedstock, allowing for precise and safe 3D object construction.
Implementation Method 1
a driver roller, which the driver roller comprising a groove that is configured to (i) accept at least a portion of the wire and (ii) direct the at least the portion of the wire towards the guide
Implementation Method 2
enabling precise deposition through electrical resistance heating
Data Source
AI summary
The present disclosure provides a system for printing a three-dimensional object. The system may comprise a support for holding a portion of the object and a wire(s) source configured to hold a wire(s) of substantially the same or different diameters. The system may also comprise a print head. The print head may comprise a guide for directing the wire to the support. The system may also comprise a driver roller comprising a groove configured to contact a portion of the wire and direct the wire to the guide, and a power source in electrical communication with the wire and the support. The system may also comprise a controller configured to direct the power source to supply electrical current to the wire and the support. The electrical current may be sufficient to melt the wire when the wire is in contact with the support or the portion of the object.