Orthogonal Printhead Arrangement for 3D Printing Complex Geometries
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Solution Overview
Problem
Current three-dimensional printing technologies face challenges in providing low friction surfaces and orientations for objects due to the limitations of material ejection directions, which restrict the creation of complex geometries and require support materials for outward projections.
Innovation Solution
A printer system utilizing at least two orthogonally oriented printheads, with a controller processing image data to generate orthogonal planes, allowing one printhead to eject material perpendicular to the support member and another parallel to it, enabling the printer to move and orient printheads to accommodate various orientations and surface formations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single printhead ejects material downwardly towards the platen, then the printing process is simple and straightforward, but the ability to create complex geometries and low friction surfaces is limited
Solution Approach 1:
The printing system is segmented into multiple printheads (first printhead oriented perpendicular to platen, second printhead oriented parallel to platen) that can be independently positioned and operated. This segmentation allows each printhead to handle different ejection directions, enabling complex geometries without requiring a single complex printhead
Solution Approach 2:
The system transitions from single-direction (vertical) material ejection to multi-directional ejection by adding a second printhead that ejects material parallel to the platen surface. This dimensional addition enables creation of low friction surfaces and complex geometries that cannot be achieved with vertical ejection alone
2Manufacturing precision
If material is ejected only in vertical direction, then the printhead structure is simple, but support material is required for outward projections
Solution Approach 1:
By adding the second printhead that ejects material parallel to the platen, the system can deposit material horizontally to create low friction surfaces and outward projections without requiring vertical support structures. This eliminates the need for support material while improving surface finish quality
3Productivity
If the printhead is moved multiple times to form each layer, then layer formation is achieved, but the printing process time increases
Solution Approach 1:
The dual printhead system enables continuous material deposition from multiple directions simultaneously. The first printhead forms vertical layers while the second printhead simultaneously creates horizontal surfaces, eliminating idle movement time and maintaining continuous productive action throughout the printing process
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 creation of complex geometries with improved surface finishes by allowing material ejection in multiple directions, reducing the need for support materials and enhancing the ability to form low friction surfaces and corners.
Implementation Method 1
a first printhead oriented orthogonally to a plane of a planar support member... enable the first printhead to eject drops of material in a direction perpendicular to the plane of the planar support member
Implementation Method 2
a second printhead located at a first position that is oriented to be parallel with the plane of the planar support member... enable the second printhead to eject drops of material in a direction parallel to the plane of the planar support member
Implementation Method 3
The controller is configured to process image data to generate planes of an object to be produced that are orthogonal to one another
Data Source
AI summary
A printer that forms three-dimensional objects has two printheads, one of which is positioned to eject material drops in a direction that is parallel to a plane of a planar member on which an object is formed by the two printheads.