Multi-Nozzle 3D Extrusion for Patterned Multi-Material Printing
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Solution Overview
Problem
Existing 3D manufacturing apparatuses are limited in extruding pre-defined patterns of materials through changeable orifices, fail to provide low-cost manufacturing operations, and lack increased printing speed and the ability to work with multiple materials efficiently.
Innovation Solution
A robotic apparatus with an extruder unit featuring a plurality of nozzles with changeable orifices, a spring steel valve for contamination isolation, and motor units for controlled movement, along with a modeling platform for building multidimensional objects, allowing for concurrent forward and reverse extrusion and rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing 3D manufacturing apparatuses are used, then manufacturing operations can be performed, but they are unable to extrude pre-defined patterns of various materials through changeable orifices
Solution Approach 1:
The extruder unit is segmented into multiple nozzles (first nozzle, second nozzle, etc.), each equipped with changeable orifices that can be independently selected and positioned. This segmentation allows different materials to be extruded through different nozzles with specific pattern definitions, enabling versatile pre-defined pattern extrusion while managing complexity through modular design
Solution Approach 2:
The system implements dynamic switching between different nozzles and orifices based on the manufacturing requirements. The changeable orifices can be rotated or repositioned to select different pattern definitions, and the robotic arm dynamically switches between nozzles during the extrusion process, providing adaptability without permanent complex configuration
2Productivity
If existing 3D manufacturing apparatuses are used, then manufacturing can be performed, but printing speed is limited
Solution Approach 1:
The robotic arm performs continuous extrusion operations without interruption by seamlessly switching between nozzles and orifices. The pre-defined patterns are stored in memory and can be rapidly recalled, eliminating the need for reconfiguration between extrusion operations. This continuous operation maintains both high printing speed and precision through automated control
Solution Approach 2:
The system pre-defines multiple orifice patterns and stores them in memory before the manufacturing process begins. The robotic arm and extruder unit are pre-positioned with the required nozzles and orifices based on the CAD model requirements, allowing immediate execution of extrusion operations without setup time, thereby increasing printing speed while maintaining precision
3Adaptability or versatility
If existing 3D manufacturing apparatuses are used, then single material extrusion is possible, but multi-material manufacturing capability is lacking
Solution Approach 1:
The extruder unit is divided into multiple nozzles, with each nozzle capable of receiving and extruding different materials. The first nozzle can receive first material while the second nozzle receives second material, allowing simultaneous multi-material extrusion. This segmentation simplifies material handling by dedicating specific nozzles to specific materials while maintaining overall system versatility
Solution Approach 2:
Each nozzle is designed with universal capability to receive different materials and switch between different orifices for pattern definition. The changeable orifices can be rotated or repositioned to provide different extrusion patterns for different materials, making each nozzle multi-functional and reducing the need for separate specialized components for each material type
4Reliability
If existing 3D manufacturing apparatuses are used, then material extrusion can be performed, but cross-flow contamination occurs between materials
Solution Approach 1:
The valve system is extracted and positioned between the nozzles and the material supply lines, creating a isolation barrier. The spring-loaded valve opens only when the robotic arm is in the correct position for material deposition, preventing cross-flow contamination by physically blocking material flow when not in use. This extraction of the valve function to a specific location simplifies the overall system while maintaining reliability
Solution Approach 2:
The spring-loaded valve acts as an intermediary component between the material supply and the nozzles. It mediates material flow by opening only under specific conditions (when the robotic arm is positioned correctly), thereby preventing direct contact between different materials and eliminating cross-flow contamination while maintaining a relatively simple system architecture
Data Source
AI summary
Disclosed is a robotic apparatus for building a multidimensional object. The apparatus includes extruder unit, support structure, plurality of motor units, and modeling platform. The extruder unit receives material to build multidimensional object. The extruder unit includes plurality of nozzles, and spring steel valve. The nozzles includes changeable orifices to extrude pre-defined patterns of materials. The spring steel valve isolates cross flow contamination of materials to allow positive extrusion of materials and restricts the backflow of materials. The extruder unit moves concurrently in forward and reverse direction while extruding materials. The support structure includes sides, and rails. The sides form outer surface of support structure. The rails are integrated with sides to form multidimensional path for extruder unit. The motor units control elevation and movement of extruder unit. The modeling platform is rotatable and provides build surface to support multidimensional object. The modeling platform moves in forward and reverse direction.