Multi-Nozzle Metal Deposition with Rotary Symmetry Motion

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Solution Overview

Problem

Existing DMD systems face inefficiencies in manufacturing symmetrical workpieces with at least two rotational axes of symmetry due to increased deposition time caused by non-productive travel movements and nozzle sharing inefficiencies.

Innovation Solution

A rotary stage with independently movable and pivotable nozzles is used to perform direct metal deposition on symmetrical objects, allowing simultaneous deposition and reducing deposition time by utilizing nozzle pairs that move in a symmetrical configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple nozzles are used to simultaneously deposit different segments of the 3D object, then productivity is improved, but loss of time increases due to non-productive return travel movements

Engineering Contradiction:

Improvedeposition speedVSAvoidreturn travel time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

Instead of having multiple nozzles travel back to a start point after processing segments, the invention inverts the approach by having a single nozzle process the entire perimeter continuously while the workpiece rotates. This eliminates the return travel movement that causes time loss, as the nozzle never needs to reposition horizontally after completing a segment - it simply continues along the perimeter as the workpiece brings new segments into position.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces dynamic rotation of the workpiece on a rotary table, transforming the static multi-nozzle system into a dynamic single-nozzle system. The workpiece rotation dynamically brings different segments into the deposition position, allowing the nozzle to maintain continuous motion along the perimeter without idle return trips, thereby resolving the time loss contradiction.

Inventive Principle:

Principle #15Dynamics

2Productivity

If series of parallel nozzles are used to attend to different segment groups simultaneously, then productivity is improved, but loss of time increases due to non-productive travel movements to overcome gaps between adjacent nozzles

Engineering Contradiction:

Improvedeposition speedVSAvoidtravel time between nozzles

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The single nozzle is designed to be universal, capable of depositing material on any segment of the workpiece perimeter. Instead of having multiple specialized nozzles each assigned to specific segments, one universal nozzle services the entire perimeter by continuous motion combined with workpiece rotation, eliminating the need to overcome gaps between adjacent nozzles.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If selective nozzles are switched on/off depending on the build profile, then manufacturing precision is improved, but productivity deteriorates due to idle nozzles during the same deposition layer

Engineering Contradiction:

Improvedeposition accuracyVSAvoiddeposition speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The single nozzle maintains continuous useful action by continuously moving along the perimeter while the workpiece rotates. There are no idle periods where nozzles are switched on or off, as the single nozzle is always actively depositing material on the current segment. The workpiece rotation ensures that new segments are continuously brought into position, maintaining uninterrupted deposition and eliminating productivity loss from nozzle switching.

Inventive Principle:

Principle #20Continuity of useful action

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

The solution significantly reduces deposition time by factors of two, four, or eight, depending on the number of nozzle pairs, enhancing manufacturing throughput for symmetrical objects.

Implementation Method 1

a laser energy beam focused upon the workpiece is infused with powder metal alloy causing the alloy to become molten

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

A rotary stage provides pivotal movement to an object supported by the stage around a vertical stage axis

Methodology Applied

Scientific EffectRotational movement:

Implementation Method 3

Each of the plurality of nozzles is independently moveable along a linear axis and independently pivotable about a rotary axis for providing symmetrical movement corresponding to a symmetrical deposition configuration of the object

Methodology Applied

Scientific EffectDirect metal deposition: Deposition (physical)

Data Source

PatentEP3681694B1Apparatus for multi-nozzle metal additive manufacturing

Publication Date: 2025.10.22 DM3D TECHNOLOGY LLC

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AI summary

An assembly for rapid manufacturing of symmetrical objects by direct metal deposition is disclosed. A rotary stage provides rotational movement to an object supported by the stage around a central stage axis. Nozzles are spaced above the rotary stage for performing direct metal deposition for building an object supported by the stage. Each nozzle is independently moveable along a horizontal axis and independently pivotable, and combined, moveable along a vertical axis for providing symmetrical movement corresponding to a symmetrical deposition configuration of the object while the object is rotated around the central stage axis.