3D Printing Nozzle Local Heating for Layer Adhesion
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Solution Overview
Problem
Fused deposition modeling techniques face challenges in achieving sufficient adhesion between layers and mechanical strength in three-dimensionally shaped objects due to insufficient fusion of thermoplastic resin layers, resulting in inferior mechanical properties compared to injection-molded products.
Innovation Solution
A method and apparatus that locally heats both the front and side areas during the deposition process using a heating portion, ensuring the thermoplastic resin remains in a molten state for better adhesion and mechanical strength, involving a nozzle that injects molten resin while moving and heating the areas in front of and beside the nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fused deposition modeling is used without additional heating, then the manufacturing process is simple, but the adhesion strength between layers and mechanical strength are insufficient
Solution Approach 1:
The patent applies local quality by implementing a heating portion that selectively heats only the front area and side area where material is deposited, rather than heating the entire build plate. This localized heating approach maintains high adhesion strength at critical interfaces while keeping the overall system simple and energy-efficient.
Solution Approach 2:
The heating portion performs preliminary action by pre-heating the front area and side area before the molten material arrives. This ensures the substrate is already at the optimal temperature for adhesion when the material is deposited, preventing cooling and ensuring strong bonding without requiring continuous high-energy heating.
2Strength
If the deposition process is slowed to improve material fusion, then adhesion strength improves, but manufacturing productivity decreases
Solution Approach 1:
The heating portion maintains continuous useful action by constantly heating the front area and side area throughout the deposition process. This continuous heating ensures that the substrate remains at optimal temperature for adhesion regardless of deposition speed, allowing high-speed manufacturing without sacrificing bond strength.
Solution Approach 2:
The patent changes the temperature parameter dynamically by using the heating portion to maintain elevated temperatures in the deposition zone. This temperature control allows the material to remain in a more compliant state during deposition, improving fusion and adhesion even at higher deposition speeds where traditional methods would fail.
3Use of energy by moving object
If only the front area is heated during deposition, then energy consumption is reduced, but adhesion strength in the planar direction becomes insufficient
Solution Approach 1:
The heating portion implements local quality by differentiating between the front area (heated continuously) and other areas (heated only when needed). This selective heating of the front area and side area ensures optimal adhesion strength in the planar direction while minimizing energy consumption by avoiding unnecessary heating of the entire build plate.
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 solution enhances the adhesion strength in both the planar and vertical directions, resulting in three-dimensionally shaped objects with improved mechanical strength and stability compared to conventional fused deposition modeling methods.
Implementation Method 1
The nozzle moves while locally heating a front area and a side area by using a heating portion
Implementation Method 2
forms a three-dimensional structure by melting thermoplastic resin, extruding the material from a nozzle or the like, and depositing the material
Data Source
AI summary
A method of manufacturing a three-dimensionally shaped object includes stacking layers on a stage for manufacturing the three-dimensionally shaped object by repeating forming a desired-shape layer while moving a nozzle that injects molten thermoplastic resin. The nozzle moves while locally heating a front area and a side area by using a heating portion. The front area is located in front of the nozzle in a moving direction of the nozzle in a plan view of the stage. The side area is located beside the nozzle in the moving direction in the plan view.