Multi-Orifice Ejector Head for High-Rate Metal Drop 3D Printing
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Solution Overview
Problem
Existing metal drop ejecting 3D printers face challenges in achieving higher material deposition rates without increasing swath dimensions or requiring multiple ejector heads, which leads to issues like metal overlap and complex system design.
Innovation Solution
A single nozzle ejector head with a plurality of orifices configured to eject material simultaneously, combined with controlled actuator movements and a controller to achieve target drop spacing, allowing for increased deposition rates without significant swath enlargement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple ejector heads are used to increase material deposition rate, then productivity is improved, but device complexity increases
Solution Approach 1:
The single ejector head is segmented into multiple nozzles (e.g., 9 nozzles arranged in a 3x3 array), allowing simultaneous ejection of multiple material streams. This segmentation enables increased deposition rate without requiring multiple separate ejector heads, thus improving productivity while maintaining relatively simple device architecture.
Solution Approach 2:
Multiple nozzles are merged into a single ejector head assembly that shares common support structures, positioning mechanisms, and control systems. This combining approach allows the system to achieve the material deposition rate of multiple ejectors while avoiding the complexity of managing multiple independent ejector heads.
2Productivity
If multiple nozzles are closely spaced to increase deposition rate, then productivity is improved, but manufacturing precision deteriorates due to drop overlap
Solution Approach 1:
The nozzles are arranged in a two-dimensional array pattern (e.g., 3x3 grid) rather than a single linear row. This dimensional arrangement allows material to be deposited in a broader area simultaneously, increasing deposition rate while maintaining adequate spacing between adjacent nozzles to prevent drop overlap and preserve manufacturing precision.
Solution Approach 2:
Each nozzle in the array is positioned and oriented to deposit material in a specific local area, with spacing designed to prevent overlap. The local deposition quality is maintained at each nozzle while the collective array achieves high overall deposition rate.
3Manufacturing precision
If nozzle spacing is increased to prevent drop overlap, then manufacturing precision is improved, but productivity deteriorates due to larger swath size
Solution Approach 1:
The ejection system is segmented into multiple nozzles working in parallel. Each nozzle handles a portion of the total material deposition task, allowing individual nozzles to be spaced adequately for precision while the collective array maintains high productivity through simultaneous operation.
Solution Approach 2:
The multi-nozzle array provides multi-functionality by simultaneously depositing material across multiple locations. This allows the system to achieve both the precision of spaced nozzles and the productivity of multiple deposition points operating in parallel.
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
Enhances material deposition rates up to nine times higher than previous systems, reducing system complexity and cost by avoiding the need for multiple ejector heads and minimizing drop overlap.
Implementation Method 1
An electrical current is passed through the conductor to produce an electromagnetic field to cause the meniscus of the melted metal at a nozzle of the chamber to separate from the melted metal within the chamber and be propelled from the nozzle
Data Source
AI summary
A three-dimensional (3D) object printer has an ejector head with a single nozzle that is fluidly connected to a plurality of orifices in an orifice plate of the ejector head. An ejection of material through the single nozzle is emitted through the plurality of orifices simultaneously. In one embodiment, some of the orifices are oriented at an angle to an axis perpendicular to the orifice plate. This configuration enables a structure to be formed with a predetermined material density without needing to increase the ejection frequency significantly or requiring the printer to incorporate multiple ejector heads.