Pellet-Fed 3D Printer Extrusion to Prevent Hopper Bridging
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Solution Overview
Problem
The bridging phenomenon occurs when sticky pellets are fed through a hopper into the cylinder of an extruder, leading to insufficient feeding and molding defects, while fluctuations in strand thickness result in defective sites within the molded object, and CT scans are costly and inefficient for inspecting internal defects.
Innovation Solution
A thermal melting three-dimensional printer equipped with a push-in mechanism that includes a rod and driving mechanism to prevent bridging by pressing pellets into the cylinder, and a method for inspecting internal defects during molding using data such as weight and strand thickness without CT scans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pellets are fed through a hopper into the cylinder of an extruder, then the extruder can process the pellets, but the bridging phenomenon occurs causing insufficient feeding and molding defects
Solution Approach 1:
The push-in mechanism performs preliminary action by pushing pellets into the hopper before the extrusion process begins, ensuring that pellets are properly positioned and preventing the bridging phenomenon from occurring during the molding process
Solution Approach 2:
The push-in mechanism acts as an intermediary between the pellet storage and the extruder cylinder, mediating the pellet feeding process to ensure consistent and sufficient pellet supply without bridging
2Manufacturing precision
If strand thickness is not controlled during molding, then the molding process is simple, but defective sites occur where the linear resin is too thin or too thick
Solution Approach 1:
The system uses feedback by monitoring strand thickness during the molding process and adjusting parameters to maintain consistent thickness, preventing defective sites while managing process complexity through real-time control
3Measurement precision
If CT scan is used to inspect internal defects of molded objects, then inspection accuracy is high, but the cost and inspection efficiency are poor
Solution Approach 1:
The patent replaces expensive CT scan equipment with a simpler, more economical inspection method that achieves sufficient detection accuracy for internal defects, improving productivity while maintaining acceptable measurement precision
Solution Approach 2:
Instead of using complex CT scanning, the invention uses a simplified inspection approach that captures essential defect information without requiring expensive equipment, effectively copying the necessary inspection function in a more efficient manner
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
Prevents molding defects by ensuring consistent pellet feeding and allows for efficient inspection of internal defects without the need for costly CT scans, ensuring high-quality molded objects.
Implementation Method 1
melt and knead, in the cylinder, the pellets fed into the cylinder to form a molten resin
Implementation Method 2
the push-in mechanism is configured to push pellets loaded on a loading surface of the hopper into the cylinder through the raw material feed port
Data Source
AI summary
Provided is a thermal melting three-dimensional printer capable of preventing molding defects. According to the present invention, there is provided a thermal melting three-dimensional printer comprising an extruder, and a push-in mechanism, wherein the extruder includes a hopper, a cylinder, and a nozzle, the hopper is configured to feed pellets into the cylinder through a raw material feed port provided in the cylinder, the extruder is configured to melt and knead, in the cylinder, the pellets fed into the cylinder to form a molten resin and to extrude the molten resin through the nozzle to form a strand, and the push-in mechanism is configured to push pellets loaded on a loading surface of the hopper into the cylinder through the raw material feed port.