Polygonal Extrusion Nozzle Assembly for Stronger 3D Printed Layers
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Solution Overview
Problem
Existing extrusion nozzles in additive manufacturing cause porosity and reduced mechanical properties due to circular cross-sections, and frequent replacements lead to potential damage and operational challenges.
Innovation Solution
An extrusion nozzle design with a polygonal section and modular components, including an insert, outer ring, funnel-shaped body, and perforated disc, allowing for easy replacement and improved alignment, reducing turbulence and enhancing layer adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular section extrusion nozzle is used, then the manufacturing process is simple, but porosity is formed in the product section and mechanical properties are reduced
Solution Approach 1:
The extrusion nozzle is divided into modular components: a replaceable insert with the extrusion opening, an outer ring for positioning, and a connecting member for attachment. This segmentation allows the critical extrusion geometry to be optimized independently while maintaining manufacturing simplicity through standardized modular assembly.
Solution Approach 2:
The insert portion of the nozzle is given a polygonal cross-section (rectangular, triangular, or other non-circular shapes) specifically at the extrusion opening area, while the rest of the nozzle body maintains a standard cylindrical form. This local quality change improves layer adhesion and reduces porosity without complicating overall nozzle manufacturing.
2Reliability
If the extrusion nozzle is frequently replaced due to wear, then worn parts can be renewed, but operational disruptions and potential damage to other components occur
Solution Approach 1:
The nozzle is segmented into a wear-prone insert that can be independently replaced and a durable outer ring and connecting member that remain in place. This allows replacement of only the worn insert component rather than the entire nozzle assembly, reducing replacement time and operational disruption.
Solution Approach 2:
The insert is designed as a consumable component that can be easily replaced when worn. By making the insert a separate, inexpensive component rather than part of a permanent nozzle assembly, the system enables quick replacement without damaging other expensive components like the plasticizing cylinder.
3Manufacturing precision
If the insert is securely locked in the plasticizing cylinder, then positioning accuracy is improved, but replacement difficulty increases
Solution Approach 1:
The locking mechanism is segmented into an outer ring with positioning features and a separate connecting member with a releaseable junction system. This segmentation allows the insert to be securely positioned during operation while enabling easy removal when needed by actuating the junction system release mechanism.
Solution Approach 2:
The junction system between the connecting member and plasticizing cylinder is designed to be dynamically changeable - firmly locked during operation to ensure positioning accuracy, but easily releasable when replacement is needed. The outer ring provides static positioning accuracy while the connecting member provides dynamic lock/release capability.
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
The design ensures accurate centring and locking of components, reduces wear, and maintains mechanical integrity by minimizing turbulence and facilitating easy replacement of worn parts.
Implementation Method 1
a plasticizing cylinder; an extrusion nozzle made in accordance with one or more of the characteristics identified above; and a releasable junction system for connecting the plasticizing cylinder and the extrusion nozzle
Implementation Method 2
additive manufacturing or three-dimensional printing of polymers, technopolymers and composite materials
Data Source
AI summary
An extrusion nozzle of a print head for additive manufacturing, the extrusion nozzle extending about a longitudinal axis and having an insert provided with a through opening and an outer ring; and a connecting member configured to partially accommodate the insert and to define a stop element for the outer ring of the insert and provided with a hole through which the insert protrudes, and a coupling member configured to tighten the outer ring of the insert, the connecting member and a plasticizing cylinder by means of a releasable junction system.