Multi-nozzle Extruder for Simultaneous 3D Printing Support
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Solution Overview
Problem
Existing three-dimensional printing systems using single nozzle extruders are inefficient in forming objects with complex features and require additional time and resources to create support structures, as they need separate extruders and materials for object and support formation, which complicates the process and reduces productivity.
Innovation Solution
A multi-nozzle extruder system with a faceplate and valves that allows simultaneous formation of object portions and support structures using a single extruder, where the controller operates multiple nozzles to create parallel ribbons of support structures, enabling efficient use of the extruder for both object and support material without the need for different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single nozzle extruder is used to form three-dimensional printed objects, then the device complexity is reduced, but the productivity decreases and manufacturing time increases
Solution Approach 1:
The extruder is segmented into multiple nozzles (first nozzle, second nozzle, third nozzle, fourth nozzle) arranged in a faceplate, each capable of extruding material independently. This segmentation allows parallel formation of multiple support structure ribbons simultaneously, increasing productivity without requiring multiple separate extruders.
Solution Approach 2:
The multi-nozzle extruder serves multiple functions: it can form both object portions and support structures using the same extruder mechanism. The controller selectively activates different nozzles to perform different functions (object formation vs. support structure formation), eliminating the need for separate extruders for different materials.
2Productivity
If separate extruders are used to form object portions and support structures, then manufacturing precision can be maintained, but the device complexity increases and productivity decreases
Solution Approach 1:
The patent merges the functions of multiple extruders into a single multi-nozzle extruder system. The first, second, third, and fourth nozzles are integrated in one faceplate and controlled by a single controller, allowing simultaneous formation of object portions and support structures without requiring multiple separate extruder mechanisms.
Solution Approach 2:
The single multi-nozzle extruder performs multiple functions that previously required separate extruders. The controller selectively activates different nozzles to form either object portions or support structures, making the extruder system universal and eliminating the need for separate extruders for different materials.
3Productivity
If multiple nozzles are opened simultaneously to form parallel ribbons of support structure, then productivity increases, but the precision of feature formation may be compromised
Solution Approach 1:
Different nozzles are selectively activated based on the specific requirements of different regions. The controller opens specific nozzles (first, second, third, or fourth) depending on whether object portions or support structures need to be formed in particular areas, ensuring precise feature formation while maintaining high productivity through parallel ribbon formation where applicable.
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 allows for faster and more efficient production of complex objects by using a single multi-nozzle extruder to form both object portions and support structures, reducing the complexity of nozzle positioning and material management, and enabling precise feature formation with narrower swaths where needed.
Implementation Method 1
extruders that soften or melt extrusion material, such as ABS plastic, into thermoplastic material
Implementation Method 2
After each layer of the three-dimensional printed object is formed, the thermoplastic material cools and hardens to bond the layer to an underlying layer
Data Source
AI summary
A method of operating a multi-nozzle extruder in an additive manufacturing system enables support structure to be formed while an object is also being formed. The method includes opening more than one nozzle in the multi-nozzle extruder, and operating an actuator with a controller to move the multi-nozzle extruder along a path to form a first group of multiple parallel ribbons of support structure simultaneously with material extruded from the more than one open nozzle.