3D Printing Nozzle Flexure for High-Speed Ironing
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Solution Overview
Problem
3D printing at high speeds faces challenges in achieving uniform filament deposition due to non-flexing print heads leaving extra material and forming undesirable ridges during fill movements, leading to uneven print quality.
Innovation Solution
A 3D printing liquefier nozzle flexure is introduced, allowing the nozzle to move relative to the print head, accommodating resistance from excess material or imperfections, thereby enabling improved ironing and print quality by varying the distance between the nozzle and the print head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If print head moves at high speed during fill movements, then productivity is improved, but manufacturing precision deteriorates due to uneven filament deposition and ridge formation
Solution Approach 1:
The patent applies the dynamics principle by making the print head flexible rather than rigid. The print head is designed with a flexible body that allows it to dynamically adjust its position and contact force during high-speed printing. This flexibility enables the print head to adapt to variations in the printing surface and maintain consistent filament deposition even at high speeds, thereby resolving the contradiction between productivity and manufacturing precision
Solution Approach 2:
The patent changes the physical parameter of the print head from rigid to flexible. By altering the mechanical property (rigidity) of the print head, the system can maintain contact pressure and deposition consistency during high-speed movements. This parameter change allows the print head to conform to surface variations without sacrificing print speed, thus improving both productivity and manufacturing precision simultaneously
2Productivity
If non-flexing print head is used at high speed, then productivity is improved, but manufacturing precision deteriorates due to extra material deposition at 180 degree turns
Solution Approach 1:
The flexible print head design allows the system to maintain high productivity while improving material deposition consistency. During high-speed printing with 180 degree turns, the flexible print head can dynamically adjust its position and flexibility to prevent material accumulation at turn-around points, thereby maintaining deposition consistency without sacrificing print speed
3Device complexity
If rigid print head structure is used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to accommodate surface imperfections
Solution Approach 1:
The patent changes the structural parameter of the print head from rigid to flexible. This parameter change allows the print head to accommodate surface imperfections and variations in the printing surface, thereby improving print quality. The flexible structure maintains relatively simple device complexity while significantly enhancing manufacturing precision through its ability to conform to surface variations
Data Source
AI summary
An apparatus, system and method for providing a liquefier nozzle flexure to at least enable ironing of a 3D print, to thereby improve print quality. The apparatus, system and method may include: a controllable print head for providing the 3D print; a liquefier capable of liquefying deposit material for providing the 3D print; and the liquefier nozzle flexure mounted between the print head and the liquefier that allows a distance between the print head and the liquefier to vary when a resistance is encountered at a print nozzle tip.