Plasticizing Unit for 3D Droplet Deposition
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Solution Overview
Problem
Current methods for producing plastic parts in small batch sizes or prototypes struggle to replicate the precision and cost-effectiveness of injection molding, particularly in achieving complex geometries with short delivery times and specific material properties.
Innovation Solution
A method and device utilizing a plasticizing unit to generate and arrange droplets of plasticized material in a laminar source flow, allowing for precise control over droplet formation and placement, independent of starting materials, enabling the creation of three-dimensional objects with complex geometries using a pressurized material store and discharge unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used for large batch sizes, then manufacturing precision and productivity are improved, but adaptability to small batch sizes and short delivery times deteriorates
Solution Approach 1:
The injection molding process is segmented into discrete droplet ejections, where each droplet represents a small unit of material that can be precisely controlled and placed. This segmentation allows the system to transition from continuous batch production to discrete, on-demand droplet deposition, enabling both high precision and adaptability to small batch sizes.
Solution Approach 2:
The system employs periodic ejection of droplets through a discharge unit, where material is delivered in controlled intervals rather than continuously. This periodic action allows for precise timing and placement of each droplet, enabling complex geometry construction while maintaining productivity through rapid sequential deposition.
2Adaptability or versatility
If prototyping methods are used for small batch sizes, then adaptability is improved, but manufacturing precision and material properties deteriorate
Solution Approach 1:
The system replaces traditional mechanical prototyping methods with a controlled droplet ejection mechanism. Instead of using manual or semi-automatic prototyping processes, the invention employs a precisely controlled discharge unit that ejects droplets with accurate positioning, enabling complex geometries to be built with high precision through automated sequential deposition.
Solution Approach 2:
The system changes key parameters including droplet size, ejection frequency, and material temperature to optimize both precision and adaptability. By controlling droplet diameter, ejection timing, and material flow rate, the system achieves high manufacturing precision while maintaining flexibility for small batch production and short delivery times.
3Adaptability or versatility
If droplet ejection is used for 3D object construction, then adaptability to different materials is improved, but device complexity increases
Solution Approach 1:
The discharge unit is designed with multi-functionality to handle different material types including thermoplastics, elastomers, and composite materials. The same basic ejection mechanism can process various materials by adjusting parameters such as temperature, pressure, and ejection frequency, reducing the need for multiple specialized devices while maintaining adaptability.
Solution Approach 2:
The system manages device complexity by controlling material properties through parameter changes rather than requiring complex mechanical modifications. By adjusting temperature, pressure, and flow rate parameters, the same plasticizing and discharge units can handle diverse materials, reducing overall system complexity while maintaining universal adaptability.
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 production of precise, complex three-dimensional objects with a wide range of materials, allowing for multi-component processes and efficient mixing of materials, reducing dependency on special materials and achieving high precision and flexibility in manufacturing.
Implementation Method 1
processing a solidifiable material or a plasticizable material such as melted plastic in the smallest output form such as droplet form in the liquid state
Implementation Method 2
A pressure is generated on the fluid phase in the material reservoir (2)
Implementation Method 3
Depending on the parameters pressure and temperature in the material reservoir (2) as well as depending on the opening time and geometry of the pulsable discharge unit (3), a discontinuous droplet (5) is generated
Implementation Method 4
The discharged drops (5) reach the object carrier (4) and build up the object (6) there
Data Source
Figure 1
Figure 2
AI summary
The production of three-dimensional object (6) from solidifiable material by sequential discharge of pressure drops, comprises plasticizing the solidifiable material in fluid phase by transferring the solidifiable material into the fluid phase by a plasticizing unit (1), feeding the fluid phase into a material storage device (2) with an intermittently operatable discharge or application unit (3), and discharging the drops through an outlet opening using the discharge or the application unit into a design space (7) for the three-dimensional object to be manufactured. The production of three-dimensional object (6) from solidifiable material by sequential discharge of pressure drops, comprises plasticizing the solidifiable material in fluid phase by transferring the solidifiable material into the fluid phase by a plasticizing unit (1), feeding the fluid phase into a material storage device with an intermittently operatable discharge or application unit, and discharging the drops through an outlet opening using the discharge or the application unit into a design space for the three-dimensional object to be manufactured. The design space and the outlet opening are moved relative to one another in the design space. The attachment of a plasticizing unit that is well-known in the injection molding technology to the material storage device that can be kept under pressure for feeding of the fluid phase into the material storage device. The pressure is applied on the fluid phase in the material storage device and produces a discontinuous trickle with a desired volume and a desired flight speed along the direction of the design space in direct relation to the intermittently operatable discharge or the application unit as a function of the pressure and temperature parameters in the material storage device and/or depending upon the opening time and geometry of the intermittently operatable discharge or the application unit. The plasticizing unit is directly attached to the material storage device and applies the pressure on the fluid phase that is homogenized by the treatment process. The fluid phase has a frontal laminar flow with flow speeds up to 10,000 m/s for the transition of the solidifiable material into the fluid phase. The dynamic viscosity number of the solidifiable material lies between 100-10,000 (Pas). The solidifiable material is a plastic or a resin that is common in the injection molding process. The desired volume of the droplet lies in the range of about 0.1 mm 3>. The opening time is lesser than or equal to 1 ms and/or the diameter of the outlet opening is 0.1 mm. For influencing the shape of the drops, sensors adjust the parameters of the plasticizing unit, pressure and/or temperature in the material storage, the discharge or the application unit and/or the closure unit through which the solidifiable material arrives at the outlet opening. The parameters comprise discharge velocity of the material from the plasticizing unit, pressure in the plasticizing unit, temperature in the plasticizing unit, temperature of the discharge or the application unit and/or the outlet opening, diameter and/or annular gap of the outlet opening in the region of the closure unit, length of the outlet opening, frequency and pitch of the closure unit, pressure of the carrier medium in the outlet unit, volumetric flow rate of the carrier medium and temperature of the material in the outlet unit. The parameters of the design space have the temperature, pressure and atmosphere of the design space. The sensors influence the speed and/or direction, with which the discharge or the application unit and/or the object carrier can be moved relative to one another. The parameters of the current application site comprise temperature and area of the current application site. The temperature of the object surface can be controlled by a temperature control unit for partially and completely dissolving the transitions between the individual drop-like parts. Several discharge or application units discharge different materials and/or apply the material at the same point in such a manner that the materials unite at the point. An independent claim is included for a device for the production of three-dimensional object from solidifiable material.