Narrow-Profile FFF Hot End for Deep-Cavity Printing
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Solution Overview
Problem
Conventional 3D printers face limitations in printing complex geometries and steep surfaces due to the design of their hot ends, which restrict their ability to 'plunge' into deep cavities and print adjacent to existing objects, often relying on two-dimensional tool paths and lacking flexibility in handling varied surface orientations.
Innovation Solution
The development of a hot end with a narrow profile and a total included angle of less than or equal to sixty degrees and greater than or equal to ten degrees, incorporating a heater, temperature sensor, heat sink, and cooling delivery system, all contained within a defined volume, allows for improved 3D printing capabilities by enabling deeper penetration and printing on non-perpendicular surfaces, and can be tailored for specific applications and printer types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional hot end design is used, then the structure is simple and easy to manufacture, but the ability to print in deep cavities and on steep surfaces is limited
Solution Approach 1:
The patent applies nesting by placing the heat sink inside the cone-shaped volume defined by the nozzle target point and the total included angle. The heater, temperature sensor, and material delivery channel are also nested within this constrained volume, creating a compact integrated assembly that enables deep cavity penetration while maintaining structural organization
Solution Approach 2:
The patent transitions from conventional linear or block-shaped hot end designs to a cone-shaped volume definition approach. By specifying all components must fit within a cone defined by total included angle and height, the design enables three-dimensional spatial optimization that allows deeper penetration while keeping the profile narrow
2Adaptability or versatility
If the hot end profile is narrowed to enable deep cavity printing, then the ability to print adjacent to existing objects improves, but the space for cooling and heating components is reduced
Solution Approach 1:
The patent uses parameter changes by defining the total included angle as a specific range (10-60 degrees) and the cone height as a multiple of the nozzle orifice size (50-250 times). These parameter specifications optimize the balance between narrow profile for adaptability and sufficient volume for component placement
Solution Approach 2:
The cooling delivery system, heater, and other components are nested within the cone-shaped volume. The heat sink is positioned to receive cooling air while remaining within the angular constraints, maximizing space utilization in the limited volume
3Length of moving object
If all components are contained within a defined cone volume, then the hot end can plunge into deep cavities, but the arrangement and assembly of components becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the hot end into distinct functional modules: nozzle assembly, heater assembly, temperature sensor, material delivery channel, and cooling delivery system. Each module can be designed and manufactured separately, then assembled into the final cone-configured hot end, making the complex design more manufacturable
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 design enhances the ability to use three-dimensional tool paths, increases the capability to print in deep cavities, and facilitates printing adjacent to existing objects, offering improved flexibility and adaptability in 3D printing processes across various printer types and sizes.
Implementation Method 1
a heater; a temperature sensor coupled with the heater
Implementation Method 2
a heat sink coupled with the FFF material delivery channel
Implementation Method 3
a heat sink coupled with the FFF material delivery channel
Implementation Method 4
the cooling delivery system can include air ducting configured and arranged to direct blown air to both the heat sink and material extruded by the nozzle
Data Source
AI summary
A hot end associated with an extruder for a Fused Filament Fabrication (FFF) three dimensional (3D) printer includes, in at least one aspect of the subject matter described in this specification: a heater; a temperature sensor coupled with the heater; an FFF material delivery channel; a heat sink coupled with the FFF material delivery channel; a nozzle coupled with the FFF material delivery channel and with the heater, the nozzle having a total included angle of less than or equal to sixty degrees and greater than or equal to ten degrees, with respect to a nozzle target point; and a cooling delivery system for at least the heat sink; where the heat sink, the heater, the temperature sensor, the FFF material delivery channel, the nozzle, and the cooling delivery system are all contained within a volume defined by the total included angle with respect to the nozzle target point.