Piezoelectric Actuated 3D Printing Nozzle for Clogging Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems face issues with nozzle clogging due to the addition of fillers, inaccurate tool touch-off, and horizontal deflection of the nozzle caused by perpendicular vibrations, leading to print inaccuracies and defects.
Innovation Solution
The integration of piezoelectric transducers aligned coaxially with the additive manufacturing nozzle applies longitudinal vibrations to prevent agglomeration and clogging, while also enabling automated tool touch-off by detecting voltage changes when the nozzle contacts the print surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piezoelectric transducers are mounted perpendicular to the nozzle to prevent clogging, then vibration is applied to the print material, but the nozzle deflects horizontally causing print inaccuracies
Solution Approach 1:
The patent inverts the conventional perpendicular mounting approach by mounting the piezoelectric transducer in-line with the nozzle axis. This reversal changes the vibration direction from horizontal (perpendicular) to longitudinal (axial), eliminating nozzle deflection while maintaining clogging prevention through axial vibrations that agitate the print material flow.
2Manufacturing precision
If filler is added to print material to adjust properties, then desired material properties are achieved, but nozzle clogging likelihood increases
Solution Approach 1:
The patent employs mechanical vibrations generated by the in-line piezoelectric transducer to continuously agitate the print material as it flows through the nozzle. These axial vibrations prevent filler particles from settling and agglomerating, maintaining flowability even with high filler content materials while preserving the desired printed part properties.
3Ease of operation
If separate conductive element is used for tool touch-off, then touch-off can be performed, but accuracy is reduced and system complexity increases
Solution Approach 1:
The patent merges the piezoelectric transducer with the nozzle assembly, eliminating the need for a separate conductive touch-off element. The integrated transducer serves dual purposes: generating vibrations for clogging prevention and detecting contact with the build plate through electrical signals, thereby improving accuracy while reducing system complexity.
Solution Approach 2:
The piezoelectric transducer is designed to perform multiple functions: (1) generating mechanical vibrations to prevent nozzle clogging, and (2) serving as a contact sensor for automated tool touch-off. This multi-functionality eliminates the need for separate components and improves measurement precision by using the same precise positioning mechanism for both extrusion and touch-off detection.
4Reliability
If perpendicular vibrations are applied to the nozzle, then print material agglomeration occurs is prevented, but horizontal deflection causes additive manufacturing errors
Solution Approach 1:
The patent inverts the vibration application direction from horizontal (perpendicular to nozzle axis) to longitudinal (parallel to nozzle axis). This inversion maintains the beneficial effect of preventing material agglomeration through vibration while eliminating the harmful horizontal deflection that causes bed adhesion problems and inaccurate print lines.
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 effectively prevents nozzle clogging and improves print accuracy by ensuring that vibrations are applied in-line with the nozzle flow, and automates the tool touch-off process for precise Z-zero setting, enhancing overall additive manufacturing performance.
Implementation Method 1
a piezoelectric transducer configured to cause a longitudinal vibration along the vertical axis
Implementation Method 2
responsive to detecting a voltage increase caused by the nozzle contacting the print surface
Data Source
AI summary
A piezoelectric printhead having a printing nozzle, and a piezoelectric transducer mounted in-line with the printing nozzle is disclosed. The piezoelectric transducer may apply vibration to the printing nozzle that is in-line with the flow of print material through the nozzle. The vibration applied to the printing nozzle may prevent agglomeration of print material as the print material flows through the nozzle by introducing heat to the print material and providing acoustic vibration to the print material, thereby reducing the viscosity of the print material. Additionally, the piezoelectric transducer may be used to set a Z-zero by contacting the nozzle with the print surface, which may generate a voltage change in the piezoelectric transducer. Z-zero may then be set responsive to detecting the voltage change.