Nozzle Holder Cooling Chamber Filament Leakage
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Solution Overview
Problem
Additive manufacturing machines face issues with molten filament leakage at the nozzle tip, inefficient cooling of deposited filament, and instability in nozzle and print plate movements, leading to inaccuracies, increased print time, and material wastage.
Innovation Solution
A system comprising a filament extrusion assembly, a nozzle holder with a protruded portion, and a nozzle assembly with a cooling chamber and sealing members to minimize leakage, combined with an integrated cooling system and a stable movement mechanism to enhance printing precision and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the filament is retracted to reduce leakage of molten filament at the nozzle tip, then the leakage is reduced, but the time involved to retract and then extrude the filament increases, thereby increasing the print time
Solution Approach 1:
The system performs preliminary cooling of the filament immediately after extrusion before the nozzle is moved or stopped. The cooling chamber and cooling fans are activated continuously during extrusion, so that when printing pauses, the filament is already cooled and solidified, eliminating the need for retraction and subsequent re-extrusion, thus reducing idle time.
Solution Approach 2:
The cooling mechanism operates continuously during the extrusion process without interruption. The cooling fans blow cooled air through the cooling chamber along the entire path of the extruded filament, maintaining continuous cooling action that ensures the filament solidifies in place, eliminating the need for retraction operations and maintaining continuous productive action.
2Object-generated harmful factors
If the filament is retracted to reduce leakage of molten filament at the nozzle tip, then the leakage is reduced, but the mechanical performance of the additive manufacturing machines is reduced
Solution Approach 1:
The system performs preliminary cooling of the filament immediately after extrusion before the nozzle is moved or stopped. The cooling chamber and cooling fans are activated continuously during extrusion, so that when printing pauses, the filament is already cooled and solidified, eliminating the need for retraction and subsequent re-extrusion, thus reducing idle time.
Solution Approach 2:
The cooling mechanism operates continuously during the extrusion process without interruption. The cooling fans blow cooled air through the cooling chamber along the entire path of the extruded filament, maintaining continuous cooling action that ensures the filament solidifies in place, eliminating the need for retraction operations and maintaining continuous productive action.
3Temperature
If cool air is blown towards the print plate to cool the molten filament, then the cooling effect is achieved, but the cool air flows in all directions and is not localised, resulting in slow cooling and requiring more cool air to be pumped in
Solution Approach 1:
The cooling system is designed to provide localized cooling directly at the extrusion point and along the filament path. The cooling chamber is positioned to receive filament immediately upon extrusion, and cooling fans direct cooled air specifically through the chamber along the filament trajectory, rather than blowing air broadly towards the print plate. This localized approach concentrates cooling effort where it is most needed, improving efficiency and reducing energy consumption.
4Ease of operation
If the nozzle moves along a rod assembly to enable movement along different axes, then the printing capability is achieved, but the rod assembly is not stable and prone to twisting and sagging, resulting in flawed printing
Solution Approach 1:
The patent replaces the traditional rod assembly mechanical guidance system with a direct-drive mechanism where the nozzle assembly is moved along the print plate using a belt-driven system with linear guides. This substitution eliminates the rod assembly that was prone to twisting and sagging, while maintaining the capability to move the nozzle along multiple axes for precise printing positioning.
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
The system reduces filament leakage, improves cooling efficiency, and increases the stability of the nozzle and print plate movements, resulting in more accurate and faster printing with reduced material wastage.
Implementation Method 1
The cool air blown towards the print plate, flows in all directions and is not localised. This results in slow cooling of the molten filament and the machine needs to pump in more cool air in order to cool the molten filament.
Data Source
AI summary
A system for feeding filament to a nozzle in an additive manufacturing machine is provided. A filament extrusion assembly is configured to extrude the filament from a spool. A nozzle holder comprises a protruded portion. The nozzle holder defines a through hole which extends into the protruded portion. The through hole receives the filament extruded by the filament extrusion assembly. The protruded portion is located immediately below a point where the filament exits the filament extrusion assembly. A nozzle assembly comprises a cooling chamber which defines a through hole aligned with the through hole of the nozzle holder. The cooling chamber defines at least one groove coaxial with the through hole of the cooling chamber. The groove receives at least one sealing member wherein the groove is defined where the nozzle holder interfaces with the cooling chamber.