Multiaxial Needle Deposition for Multi-Material Direct Writing
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Solution Overview
Problem
Existing additive manufacturing methods are limited by the need to control multi-extrusion head nozzles, allowing only single-material deposition, and commercial nozzle options have limited deposition capability for mixing materials.
Innovation Solution
The use of coaxial, triaxial, and multiaxial material feeds that allow precise integration and delivery of multiple feedstocks, including thixotropic materials, without heating, through a multiaxial needle arrangement with electronically controlled pumps, enabling simultaneous deposition of discrete phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple extrusion head nozzles are used to deposit multiple materials, then multi-material deposition capability is improved, but device complexity and control difficulty increase significantly
Solution Approach 1:
The patent divides the single nozzle into multiple independent axial passages (first axial passage, second axial passage, etc.), each capable of delivering a different feedstock. This segmentation allows multiple materials to be deposited through a single nozzle structure, achieving multi-material deposition capability while avoiding the complexity of controlling multiple separate extrusion heads.
Solution Approach 2:
The patent merges multiple feedstock delivery pathways into a single multiaxial nozzle structure with a common outlet. Multiple axial passages converge at a single outlet point, allowing simultaneous deposition of multiple materials from one nozzle. This combining approach simplifies the overall system architecture compared to using multiple separate nozzles.
2Productivity
If external heating is applied to melt feedstocks for deposition, then material flow and deposition capability are improved, but temperature control complexity and energy consumption increase
Solution Approach 1:
The patent employs pumps (first pump, second pump, etc.) to actively pressurize and deliver feedstocks through the axial passages without requiring external heating. The system uses mechanical pressure to achieve material flow and deposition, making the process independent of thermal softening or melting. This self-service approach eliminates the need for complex temperature control systems.
Solution Approach 2:
The patent replaces the thermal field (heating system) with a mechanical field (pump-driven pressure system). Instead of using heat to melt and flow materials, the system uses mechanical pressure from pumps to force feedstocks through the nozzle and achieve deposition. This substitution eliminates temperature control complexity and energy consumption associated with heating.
3Ease of operation
If pre-compounded filaments or pastes are used, then material deposition is simplified, but material composition flexibility and multi-material integration are reduced
Solution Approach 1:
The patent maintains separate axial passages for different feedstocks from preparation to deposition, allowing each material to be independently controlled and delivered. This segmentation enables the system to handle diverse material compositions (liquids, pastes, suspensions, etc.) with different properties while maintaining simple deposition operation through automated pump control.
Solution Approach 2:
The patent creates a universal deposition system that can handle multiple material types and compositions through a single multiaxial nozzle. The system is designed to accommodate various feedstock forms (liquids, pastes, suspensions) and can be programmed to deposit them in different patterns and sequences, achieving both ease of operation and material flexibility.
4Ease of manufacture
If traditional screw extruders are used for in-line blending, then material mixing is achieved, but deposition precision and geometric complexity are limited
Solution Approach 1:
The patent delivers different feedstocks through separate axial passages to the common outlet, maintaining material separation until the point of deposition. This segmentation approach allows for precise control of material placement and geometric formation, achieving high deposition precision and geometric complexity that cannot be obtained with traditional in-line blending methods.
Solution Approach 2:
The patent performs material preparation and loading in advance into separate reservoirs connected to the multiaxial nozzle. Feedstocks are pre-prepared and stored separately, then delivered on-demand through the axial passages. This preliminary action allows for precise control of material deposition timing and location, enabling complex geometric fabrication with high precision.
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 the fabrication of complex geometries and structures by allowing simultaneous deposition of multiple materials with varying properties, facilitating the creation of parts with integrated functionalities that were previously unattainable.
Implementation Method 1
At least the first and second feedstocks are combining to a common outlet of the multiaxial needle, forming a single multicomponent deposition material having multiple discrete phases
Implementation Method 2
The first pump is configured to pressurize and deliver a first fluid feedstock from a first reservoir to a first inlet of the multiaxial needle
Implementation Method 3
The second pump is configured to pressurize and deliver a second feedstock from a second reservoir to a second inlet of the multiaxial needle
Implementation Method 4
The multicomponent deposition material is deposited from the common outlet onto a substrate
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An embodiment of a method for operating a direct write device includes operating a first pump (52) to deliver a first fluid feedstock (56) to a first inlet (84) of a multiaxial needle (82) and operating a second pump (58) to deliver a second feedstock (62) to a second inlet (86) of the multiaxial needle (82). At least the first (56) and second (62) feedstocks are simultaneously drawn or injected through respective first and second axial passages (98A, 98B; 99A, 99B) in the multiaxial needle (82). At least the first (56) and second (62) feedstocks are combining to a common outlet (90) of the multiaxial needle (82), forming a single multicomponent deposition material having multiple discrete phases without applying external heat to the first (56) or second (62) feedstocks within the needle (82). The multicomponent deposition material is deposited from the common outlet (90) onto a substrate.