Additive Manufacturing Print Head With Eccentric Cam Roller Feeding
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Solution Overview
Problem
Continuous fiber 3D printing faces challenges in ensuring proper wetting of fibers with the matrix, cutting, automated restarting, and curing of the matrix-coated fibers, which affects the strength and quality of the fabricated structures.
Innovation Solution
A print head system with a receiving end for the matrix and continuous reinforcement, featuring a guiding module for alignment, a feeding mechanism with eccentric cam rollers for controlled discharge, a cutting module for precise cutting, and a compacting module for ensuring proper matrix impregnation and curing, along with a curing module for energy exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber reinforcement is used in 3D printing, then the strength of the composite structure is improved, but the difficulty of ensuring proper wetting of fibers with matrix increases
Solution Approach 1:
The patent applies preliminary action by pre-impregnating the continuous fibers with matrix material before they enter the printing head. The impregnation module coats the fibers with matrix material upstream of the discharge point, ensuring proper wetting occurs before the fibers are deposited. This preliminary impregnation resolves the wetting difficulty by performing the coating action in advance rather than attempting to wet fibers during the high-speed printing process.
Solution Approach 2:
The patent introduces an intermediary impregnation module between the fiber supply and the printing head discharge. This intermediate component serves as a mediator that applies matrix material to the fibers, facilitating proper wetting without requiring direct intervention during the printing operation. The intermediary module decouples the wetting function from the printing function, resolving the technical contradiction.
2Productivity
If automated restarting after fiber cutting is implemented, then the productivity of the printing system is improved, but the device complexity increases
Solution Approach 1:
The patent implements self-service through an automated fiber cutting and restarting mechanism. The printing head system automatically detects when fibers need cutting, performs the cutting operation, and initiates restarting of new fibers without external intervention. This automation resolves the contradiction by making the system self-sufficient, thereby improving productivity while the complexity is contained within the automated subsystem.
Solution Approach 2:
The patent replaces manual mechanical operations with automated control systems for fiber cutting and restarting. Instead of manual intervention to cut and restart fibers, the system uses automated sensing and actuation mechanisms that can detect fiber status and perform necessary operations automatically, thereby improving productivity while containing complexity within the control system.
3Manufacturing precision
If precise cutting of continuous fibers is performed, then the manufacturing precision of the composite structure is improved, but the speed of the printing process decreases
Solution Approach 1:
The patent maintains continuity of useful action by implementing continuous fiber feeding with automated cutting. The fiber supply operates continuously without interruption, and the cutting operation is performed automatically at precise intervals or positions without stopping the overall printing process. This continuous operation resolves the contradiction by maintaining high speed while achieving precise cutting through automated timing or position-based triggering.
Solution Approach 2:
The patent applies preliminary action by pre-positioning or pre-aligning fibers before the cutting point, and by having the cutting mechanism ready in advance. The system prepares the cutting operation beforehand so that when cutting is required, it can be executed quickly and precisely without disrupting the printing speed. This preliminary preparation resolves the speed-precision contradiction.
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 system ensures proper alignment, impregnation, and curing of continuous reinforcements, enhancing the strength and quality of the composite structures by addressing the issues of fiber wetting, cutting, and restarting, resulting in improved structural integrity and manufacturing efficiency.
Implementation Method 1
exposing the matrix to a cure energy after compacting
Data Source
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AI summary
A print head is disclosed for use in an additive manufacturing system. The print head may include a receiving end configured to receive a matrix and a continuous reinforcement, and a discharging end configured to discharge the continuous reinforcement at least partially coated in the matrix. The print head may also include a compactor located at the discharging end and forming a tool center point for the print head.