Multi-Nozzle Extrusion Head for Faster Thin-Layer Deposition
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Solution Overview
Problem
Existing additive manufacturing techniques using viscous materials, such as thermoset materials, face slow deposition speeds and extended manufacturing times due to the use of small-diameter filaments, especially when forming thin layers.
Innovation Solution
An extrusion head with a supply chamber and multiple nozzles arranged adjacently, featuring a progressive cross-section extrusion channel and adjustable nozzle spacing, allowing simultaneous deposition of multiple filaments to form a strip, with controlled thickness and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small-diameter filaments are used to form thin layers, then coating thickness precision is improved, but manufacturing time increases significantly
Solution Approach 1:
The invention divides the single extrusion function into multiple nozzles (e.g., 5 nozzles arranged in a line), each depositing a filament simultaneously. This segmentation allows parallel deposition of multiple filaments, forming a complete coating layer in one pass rather than requiring sequential deposition of many thin filaments, thus reducing manufacturing time while maintaining precise thickness control through controlled nozzle spacing.
Solution Approach 2:
The invention merges multiple extrusion operations into a single simultaneous operation. Multiple nozzles are integrated into one extrusion head assembly, allowing concurrent deposition of multiple filaments that together form the complete coating layer. This combining of parallel operations into one synchronized action eliminates the time required for sequential layer-by-layer or filament-by-filament deposition.
2Productivity
If multiple nozzles are added to deposit filaments simultaneously, then productivity is improved, but device complexity increases
Solution Approach 1:
The extrusion head design integrates multiple nozzles into a single functional unit that serves the universal purpose of coating deposition. All nozzles share common material supply, positioning, and control mechanisms, allowing the system to handle different coating requirements (thickness, width, pattern) by adjusting operational parameters rather than requiring separate specialized devices for each configuration.
Solution Approach 2:
The invention applies local quality by allowing different nozzles to have slightly different characteristics (e.g., varying outlet diameters or positions) to optimize deposition for specific local requirements. The nozzle array can be configured with non-uniform spacing or varying orifice sizes to accommodate different coating thickness requirements across the width of the substrate, while maintaining overall system simplicity.
3Manufacturing precision
If nozzle spacing is reduced to deposit thinner layers, then coating thickness precision is improved, but manufacturing time increases
Solution Approach 1:
The invention transitions from one-dimensional sequential deposition (single nozzle moving across the substrate) to two-dimensional parallel deposition (multiple nozzles arranged in an array). By adding the spatial dimension of multiple nozzles positioned at different locations across the substrate width, the system can deposit entire coating layers simultaneously rather than sequentially, achieving both thin layer precision and rapid deposition.
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
Significantly reduces manufacturing time and enhances the homogeneity and uniformity of deposited layers, facilitating cleaning and enabling deposition on various surface geometries.
Implementation Method 1
an inlet port opening into the supply chamber and configured to receive a material to be extruded under pressure
Data Source
AI summary
An extrusion head for additive manufacturing includes an enclosure defining a supply chamber. The enclosure includes at least one inlet port opening into the supply chamber and configured to receive a material to be extruded under pressure and a plurality of extrusion nozzles. Each nozzle is in communication with the supply chamber and opens onto the exterior of the enclosure via an outlet orifice. The nozzles of the plurality of nozzles are arranged adjacent to one another with a determined spacing between each nozzle outlet orifice.