Multi-Nozzle 3D Printer Extruder with Dispenser
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Solution Overview
Problem
Existing three-dimensional printing technologies face challenges with single-nozzle printheads, which either take too long to form objects or sacrifice detail for speed, and multi-nozzle solutions either increase printer complexity or require separate material supplies.
Innovation Solution
A multi-nozzle extruder with a dispenser system that allows extrusion material to be supplied to multiple nozzles from a single source, enabling simultaneous or alternating operation of multiple nozzles with a single material supply, and a valve assembly for precise control of extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single printhead with a single nozzle is used, then the device complexity is low, but the printing speed is slow and productivity is reduced
Solution Approach 1:
The printhead is segmented into multiple nozzles (first nozzle, second nozzle, third nozzle, fourth nozzle) arranged in a linear array, allowing simultaneous extrusion of build material through multiple channels. This segmentation enables parallel material deposition, significantly increasing printing speed and productivity while maintaining a relatively simple overall printhead structure.
Solution Approach 2:
The single printhead with multiple nozzles serves multiple functions: it can extrude build material through different nozzle diameters (larger nozzles for faster deposition, smaller nozzles for finer detail) and can selectively activate different nozzles based on printing requirements. This multi-functionality allows the system to achieve both high speed and high detail in different regions of the print without requiring multiple separate printheads.
2Productivity
If a printhead with a larger nozzle diameter is used, then the printing speed increases, but the manufacturing precision and detail quality deteriorate
Solution Approach 1:
Different nozzles in the array have different diameters optimized for different purposes: larger nozzles (first and second nozzles) are positioned for high-speed deposition in regions requiring faster printing, while smaller nozzles (third and fourth nozzles) are positioned for fine detail work in regions requiring higher precision. The system selectively activates appropriate nozzles based on local printing requirements, achieving both speed and detail quality in different areas of the same print.
3Productivity
If multiple independent printheads are used, then the printing speed and productivity improve, but the device complexity and material supply requirements increase
Solution Approach 1:
Multiple nozzles that would traditionally require separate printheads are merged into a single integrated printhead assembly. All nozzles share a common mounting structure and can be controlled by a single printhead positioning system. The build material supply is merged into a single reservoir that feeds all nozzles through individual channels, eliminating the need for multiple material supply systems while maintaining the productivity benefits of multiple extrusion points.
4Manufacturing precision
If heaters and drive motors are frequently activated and deactivated, then the control precision is improved, but the printing speed and productivity are reduced
Solution Approach 1:
The multiple nozzles are designed to maintain continuous extrusion of build material without frequent start-stop cycles. By having multiple nozzles available, the system can continuously deposit material through different nozzles as the printhead moves, eliminating idle time between extrusion operations. This continuous action maintains both precision (through consistent material flow) and speed (by eliminating interruptions).
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 solution enhances printing speed and precision by allowing for the simultaneous operation of multiple nozzles with a single material supply, reducing complexity and improving the ability to form detailed structures quickly.
Implementation Method 1
an actuator configured to move the outlet into alignment with at least two channels in the plurality of channels at different times
Implementation Method 2
an extrusion printhead emits a melted build material, such as heated and softened ABS plastic
Implementation Method 3
The printer typically operates the extrusion printhead to form successive layers of the build material that form a three-dimensional printed object... emits build material that cools and hardens after extrusion
Data Source
AI summary
A three-dimensional object printer includes a multi-nozzle extruder, at least one extrusion material supply, and a dispenser that provides extrusion material from the extrusion material supply to each of a plurality of channels, each channel supplying extrusion material to at least one nozzle in the multi nozzle extruder. The dispenser includes an inlet to receive extrusion material from at least one extrusion material supply, an outlet configured to direct the extrusion material to a channel in the plurality of channels, and an actuator configured to move the outlet into alignment with each channel in the plurality of channels.