Polygonal Nozzle 3D Printing Void Reduction
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Solution Overview
Problem
Existing three-dimensional forming apparatuses face challenges in minimizing voids between adjacent materials during the formation of three-dimensional objects, leading to excessive porosity and reduced strength in the final product.
Innovation Solution
A three-dimensional forming apparatus with a controller that adjusts the distance between the nozzle tip and the estimated material deposition position to ensure the ratio of the opening area to the ejected volume is less than 1.0, using a polygonal nozzle shape to effectively deposit material and reduce voids, thereby enhancing the object's porosity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the nozzle hole shape is designed to prevent unnecessary forming, then intermittent ejection problems are solved, but voids between adjacent materials remain excessive
Solution Approach 1:
The patent changes the geometric parameters of the nozzle opening from conventional circular shapes to polygonal shapes (triangle, quadrangle, pentagon, hexagon, etc.). This parameter change in the opening shape creates a corresponding polygonal cross-section in the extruded material, which effectively reduces voids between adjacent deposited materials while maintaining form integrity during intermittent ejection.
2Manufacturing precision
If material is ejected continuously to fill voids, then porosity is reduced, but deposition precision and layer control deteriorate
Solution Approach 1:
The patent applies preliminary action by designing the nozzle opening shape in advance to be polygonal, which pre-configures the extruded material shape to fit together like puzzle pieces. This preliminary geometric configuration automatically reduces voids between adjacent deposits without requiring continuous material ejection or post-processing, thereby maintaining precise deposition control while achieving void reduction.
Data Source
AI summary
A three-dimensional forming apparatus includes: an ejecting portion that ejects a forming material from an opening portion to a forming table; a moving portion that changes a relative position between the forming table and the ejecting portion; and a controller that controls the ejecting portion and the moving portion. The ejecting portion includes a tip surface having the opening portion. An external shape of the opening portion is polygonal. When the three-dimensional object is formed, the controller controls the moving portion such that a distance (Gp) between the tip surface and an estimated position to which the forming material is to be ejected from the ejecting portion satisfies the following Expression (1).(Sq1×Gp)/Vt<1.0 (1)where Sq1 represents an area of the opening portion, and Vt represents a volume of the forming material that is ejected per unit moving amount by the ejecting portion.