Paste Nozzle Serpentine Distribution for Ceramic Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing systems for ceramic parts face issues with uneven paste distribution, leading to defects, limited work surface size, and the inability to print multi-material parts, due to significant scraping forces and menisci formation.
Innovation Solution
A new paste supply system where the paste is distributed from a nozzle above the work surface, moving in a serpentine pattern to ensure even distribution, minimizing scraping effort and allowing for wider work surfaces and multi-material printing by controlling the quantity and viscosity of the paste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bead of paste is spread from an edge of the work surface using a scraper blade, then the paste can be distributed across the work surface, but significant scraping forces are generated causing parts to break or move, generating defects
Solution Approach 1:
The paste distribution process is segmented into two independent stages: first, the paste is deposited in a bead form from a nozzle along the work surface; second, the scraper blade separately performs the spreading function. This segmentation allows each component to perform its function with minimal stress - the nozzle deposits paste without contact forces, and the scraper blade only needs to move the already-positioned paste rather than pull it across the surface.
Solution Approach 2:
The paste is preliminarily positioned in a bead form along the desired path before the spreading action occurs. The nozzle deposits the paste bead in advance, creating a pre-positioned material trail that the scraper blade then simply spreads. This preliminary positioning eliminates the need for the scraper to pull paste across the surface, significantly reducing scraping forces that could damage parts.
2Length of stationary object
If the work surface length is increased to accommodate larger parts, then more paste is needed, but the scraper blade must push more dough which increases menisci formation and stresses on hardened layers
Solution Approach 1:
The paste delivery is segmented into discrete deposits along the work surface length rather than requiring a single large bead. The nozzle can deposit paste continuously or in segments as the system moves along the length, and the scraper blade processes this segmented paste distribution. This allows the work surface length to be extended without requiring the scraper to push increasingly large volumes of paste at once.
Solution Approach 2:
The paste is preliminarily deposited in a controlled bead form that matches the required layer volume for each section of the work surface. This preliminary deposition ensures that the scraper blade encounters only the necessary amount of paste at each position, preventing excessive paste accumulation that would create menisci or require excessive spreading force on extended work surfaces.
3Area of stationary object
If the piston rises higher to distribute more dough across the width, then better coverage is achieved, but excess dough accumulates in the middle of the work surface
Solution Approach 1:
The paste deposition is localized to specific positions along the work surface rather than distributing paste uniformly across the entire width from a single source. The nozzle can be positioned to deposit paste only where needed, or deposit in a pattern that matches the required layer geometry. This local quality control prevents excess paste accumulation in the middle while ensuring adequate coverage at the edges.
Solution Approach 2:
The paste is preliminarily deposited in a controlled pattern that anticipates the required distribution. Rather than depositing a large bead and relying on scraper mechanics to distribute it uniformly, the nozzle deposits paste in the final desired distribution pattern before the scraper spreads it. This preliminary action ensures homogeneous distribution without excess accumulation.
4Device complexity
If a single paste supply system is used, then the system is simple, but only one ceramic material can be printed at a time
Solution Approach 1:
The nozzle system is designed with multi-functionality to handle different paste materials. The nozzle can be configured or replaced to work with different ceramic pastes, and the deposition control system can adapt to different material properties. This universality allows a single paste supply system to print multiple material types by changing the paste supply source or nozzle configuration, rather than requiring separate systems for each material.
Solution Approach 2:
The paste supply system is made dynamic and adjustable rather than fixed. The system can change paste supply parameters, switch between different paste sources, or adjust nozzle characteristics based on the material being printed. This dynamic adaptability enables multi-material capability while maintaining a relatively simple overall system architecture.
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 solution reduces defects, enables the production of wider and taller ceramic parts, and allows for the creation of multi-material parts by ensuring uniform paste distribution and minimizing stress on already hardened layers.
Implementation Method 1
curing of said first layer by irradiation according to a pattern defined from the model for said layer
Implementation Method 2
at least one photoinitiator and usually at least one plasticizer and/or at least one dispersant; The layers are irradiated by laser scanning of the free surface of the spread photocurable composition
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3c
AI summary
The invention relates to a method for manufacturing a part, in particular a raw part in ceramic material, by the technique of additive processes according to which layers of a photocurable paste are successively hardened according to a pattern defined for each layer, the first layer being formed on a work surface on a work platform, each layer being, before its hardening according to a defined pattern, spread by scraping by a scraper blade or parallel scraper blades from a quantity of paste brought onto said work platform, which is lowered at each layer formation, characterized in that at each layer formation, the quantity of paste necessary to form said layer is distributed on the work surface from at least one nozzle (8) which is moved in front of the scraper blade, or in the case of parallel scraper blades, in front of the front scraper blade.