Multi-Nozzle 3D Printing Extruder with Remote Drive
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Solution Overview
Problem
Current FDM printing systems are limited by the need for constant nozzle changes and reduced acceleration due to increased mass with multiple nozzles, leading to decreased print speed and quality, especially when printing with larger filaments or multiple materials.
Innovation Solution
Implementing a system with multiple nozzles that can be selectively driven by a single motor using a mechanism that indexes based on reverse motion or axis displacement, and using remote filament drive motors with flexible shafts to reduce the mass of the moving print head and allow for faster filament feeding without compromising print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple nozzles are used to enable multiple materials and colors, then the versatility and functionality of the 3D printing system is improved, but the mass of the moving print head increases which reduces acceleration and print speed
Solution Approach 1:
The patent divides the filament feeding function into separate modules: a stationary filament storage and feeding system on the chassis, and a lightweight print head that only contains the nozzle assembly. This segmentation allows the heavy components to remain stationary while the lightweight head moves freely, resolving the contradiction between having multiple nozzles and maintaining high acceleration.
Solution Approach 2:
The patent introduces a flexible shaft or belt as an intermediary to transmit rotational motion from the stationary motor to the moving nozzle assembly. This intermediary allows the motor to remain stationary (avoiding mass penalty) while still providing drive force to the moving nozzle, enabling multiple nozzles without the mass penalty of moving motors.
2Productivity
If larger filaments are used to fill interior spaces faster, then productivity is improved, but heat transfer to the center of the filament is slower which compromises print quality
Solution Approach 1:
The patent segments the filament path into multiple heating zones along the extrusion path. Each zone can be independently controlled to provide sufficient heat transfer even for larger filaments, ensuring complete liquefaction without sacrificing the speed benefit of using larger filaments for filling.
Solution Approach 2:
The patent dynamically adjusts heating parameters (temperature, residence time) based on filament size and position. Larger filaments receive different thermal parameters than smaller ones, allowing the system to optimize both speed and quality simultaneously by adapting parameters to the specific filament characteristics being used.
3Adaptability or versatility
If multiple filaments are fed simultaneously through a single nozzle for mixing, then material versatility is improved, but the complexity of the feed system increases
Solution Approach 1:
The patent merges multiple filament feeding paths into a single integrated feed system that handles multiple materials simultaneously. By combining the feed mechanisms and using a unified control architecture, the system achieves multi-material capability without proportionally increasing complexity - multiple filaments share common components like the drive motor and control electronics.
Solution Approach 2:
The patent designs a universal feed system that can handle different filament types and quantities through the same basic mechanism. The single motor and feed structure can accommodate multiple nozzles and filament configurations, making the system adaptable to various material mixing scenarios without requiring separate dedicated feeds for each material.
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
Enables faster and more efficient 3D printing with multiple materials and colors by reducing the mass of the print head, maintaining high acceleration, and preventing deformation, thus improving print speed and quality.
Implementation Method 1
forcing a solid plastic feedstock through a heated nozzle with smaller diameter than the original feedstock. The filament is liquefied before or as it passes through the constriction in the nozzle
Implementation Method 2
a flexible shaft coupling the motor with the mechanical power input
Data Source
AI summary
Additive manufacturing systems and apparatus include, in one aspect, a material deposition system including an extruder for deposition materials, the extruder including two or more material entry ports, a mixing chamber, and an exit orifice; and a controller coupled with the extruder to dynamically change delivery rates of the deposition materials to be mixed in the mixing chamber before flowing from the exit orifice; wherein the controller combines a desired volume flow rate of material to flow from the exit orifice with a mix ratio to specify the delivery rates of the deposition materials. The system can include filament drive systems to feed the thermoplastic materials in filament form into the entry ports, and the controller can dynamically change the mix ratio when operating the filament drive systems to control one or more properties of the material to flow from the exit orifice.