Pin-Actuated Printhead for High Viscosity Polymer Ejection

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Solution Overview

Problem

Current additive manufacturing processes, such as 3D printing, are limited in their ability to handle high viscosity materials and create multi-material or multi-color composites due to the viscosity constraints of existing printheads, which restrict the capability to intermix deposited materials effectively.

Innovation Solution

A pin-actuated printhead system that can eject materials with viscosities of 10,000 centipoise or more by using a material delivery system to liquefy solid filaments and control the ejection of high viscosity materials through a combination of orifices, channels, and actuated pins, allowing for the deposition of various materials and colors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional inkjet printheads are used to eject materials, then the printing process is simple and straightforward, but the viscosity of the material must be 10-20 centipoise or less, limiting the ability to use high viscosity materials

Engineering Contradiction:

Improvematerial viscosity rangeVSAvoidprinthead structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The printhead is divided into multiple independent material chambers, each capable of holding and ejecting different high viscosity materials. This segmentation allows each chamber to be optimized for specific material properties while maintaining the ability to handle multiple materials simultaneously, resolving the contradiction between versatility and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the operating parameters of the printhead by using pin actuators that apply direct mechanical force to eject materials, rather than relying on conventional inkjet droplet ejection mechanisms. This parameter change enables the ejection of high viscosity materials (10,000+ centipoise) that would be impossible with standard inkjet technology.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If multiple jetted materials are used to create multi-material composites, then material variety and color options increase, but the capability to intermix deposited materials is limited

Engineering Contradiction:

Improvemulti-material composite capabilityVSAvoidmaterial intermixing

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system performs preliminary mixing of materials within the material chambers before ejection. By pre-mixing materials at the source, the system eliminates the need for complex post-deposition intermixing operations, making multi-material composite creation easier while maintaining high versatility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pin actuators serve as intermediaries that facilitate material ejection and controlled deposition. These actuators enable precise control over material placement and can facilitate the intermixing of different materials during the deposition process, resolving the contradiction between material variety and ease of intermixing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If FDM or SLS technologies are used to use extremely viscous materials, then high viscosity material processing is enabled, but the capability to print varying multi-material composites and intermix deposited materials is limited

Engineering Contradiction:

Improvehigh viscosity material handlingVSAvoidsystem configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The printhead design achieves universality by incorporating multiple material chambers and pin actuators that can handle different high viscosity materials with varying properties. This multi-functional design enables the system to process extremely viscous materials while maintaining the capability to print varying multi-material composites, reducing the need for separate specialized systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 3D printed structures using high viscosity materials, including engineering polymers and solder pastes, with improved material intermixing and color adjustment, enhancing the versatility and capability of additive manufacturing.

Implementation Method 1

Using the filament driver, the solid filament is moved into a heater to convert the solid filament into a liquid material

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

actuating a pin through the pin chamber to control ejection of the volume of liquid material from the pin chamber through an orifice

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS10442174B2Material feeder for engineering polymer ejection system for additive manufacturing applications

Publication Date: 2019.10.15 GENESEE VALLEY INNOVATIONS LLC

AI summary

A 3D printer including a pin actuated printhead having an orifice through which a material is ejected, a material chamber to hold the material to be ejected, a channel connecting the material chamber to the orifice, a pin chamber, and an actuated pin within the pin chamber, wherein the actuated pin extends through the pin chamber to eject the material from the orifice. The printhead is configured to eject a material with a viscosity of 10,000 cP or more at an elevated temperature. The 3D printer further includes a material delivery system having a filament driver and a filament heater.