Multi-nozzle 3D Shaping Device for Continuous Extrusion
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Solution Overview
Problem
Existing three-dimensional shaping devices using multiple nozzles face challenges in reducing shaping time while ensuring the integrity and strength of the formed object, as intermittent ejection can lead to voids and compromised strength.
Innovation Solution
A three-dimensional shaping device with a plasticizing unit, a stage, a ejection unit with multiple nozzles arranged side by side, an ejection switching unit for controlled ejection, and a moving unit, along with a control unit to laminate the shaping layer, allowing continuous linear ejection and precise control of the shaping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is intermittently ejected from multiple nozzles to shorten shaping time, then productivity is improved, but voids are formed in the three-dimensional shaped object and strength is compromised
Solution Approach 1:
The patent implements continuous ejection of plasticized material from multiple nozzles simultaneously, eliminating the intermittent ejection process. The ejection unit maintains continuous material flow onto the deposition surface, ensuring no voids are formed while achieving rapid shaping through parallel multi-nozzle operation. This resolves the contradiction by making the useful action (material ejection) continuous rather than intermittent.
Solution Approach 2:
The ejection unit is divided into multiple independent nozzles arranged side by side, each capable of simultaneous operation. This segmentation allows the system to process multiple sections of the shaping layer at once, achieving high productivity through parallel processing while maintaining continuous material flow from each nozzle to prevent void formation.
2Reliability
If material is ejected from one nozzle in a one-stroke manner, then the integrity of the shaped object is maintained, but shaping time becomes long
Solution Approach 1:
The single nozzle is segmented into multiple nozzles arranged side by side in the ejection unit. Each nozzle operates simultaneously to deposit material for different portions of the shaping layer, reducing the overall shaping time while maintaining continuous material flow from each nozzle to ensure integrity and prevent voids.
Solution Approach 2:
Multiple nozzle operations are merged into a single simultaneous ejection process. The ejection unit coordinates all nozzles to operate together, combining their output into a unified deposition process that achieves both high productivity through parallel processing and high reliability through continuous material flow.
3Productivity
If multiple nozzles are used to eject material simultaneously, then shaping time is reduced, but voids are unintentionally formed due to intermittent ejection
Solution Approach 1:
The system maintains continuous material flow from each nozzle in the ejection unit, eliminating the intermittent ejection that causes voids. The plasticizing unit continuously supplies molten material to the ejection unit, which in turn continuously deposits it onto the deposition surface, ensuring no gaps or voids form in the shaping layer while achieving rapid shaping through multi-nozzle parallel operation.
Solution Approach 2:
The ejection unit is segmented into multiple independent nozzles that operate simultaneously with continuous material flow from each. This segmentation enables parallel processing for high productivity while the continuous operation of each segment prevents void formation in its respective deposition area.
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 configuration enables the formation of a shaping layer in a wide range, reducing shaping time and preventing voids, thus ensuring the intended strength and integrity of the three-dimensional shaped object.
Implementation Method 1
a plasticizing unit (30) configured to plasticize a material to generate a plasticized material
Implementation Method 2
an ejection unit (60) that has a plurality of nozzles (68A to 68D) arranged side by side along a first axis parallel to the deposition surface of the stage, and that is configured to eject the plasticized material in a continuous linear form from the plurality of nozzles toward the deposition surface
Implementation Method 3
a moving unit (400) configured to move the ejection unit (60) with respect to the stage (300) along a second axis that is parallel to the deposition surface of the stage (300) and that intersects the first axis
Implementation Method 4
a control unit (500) configured to laminate a shaping layer formed of the plasticized material on the deposited surface of the stage (300) by controlling the plasticizing unit (30), the ejection switching unit (70), and the moving unit (400)
Data Source
AI summary
A three-dimensional shaping device includes: a plasticizing unit configured to plasticize a material to generate a plasticized material; a stage having a deposition surface on which the plasticized material is deposited; an ejection unit that has a plurality of nozzles arranged side by side along a first axis parallel to the deposition surface of the stage, and that is configured to eject the plasticized material in a continuous linear form from the plurality of nozzles toward the deposition surface; an ejection switching unit configured to individually switch between stopping and resuming ejection of the plasticized material from the plurality of nozzles; a moving unit configured to move the ejection unit with respect to the stage along a second axis that is parallel to the deposition surface of the stage and that intersects the first axis; and a control unit configured to laminate a shaping layer formed of the plasticized material on the deposited surface of the stage by controlling the plasticizing unit, the ejection switching unit, and the moving unit.