3D Printer Print Head Filament Path Length Adjustment
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Solution Overview
Problem
Existing slack management systems in three-dimensional printers are cumbersome, difficult to seal, and increase costs and maintenance, especially when dealing with hygroscopic materials like nylon and carbon fiber composites, as they require controlled environments to prevent oxidation and moisture exposure.
Innovation Solution
A path length adjustment system integrated into the print head of a three-dimensional printer, which includes a movable component with a passage to adjust filament length in response to pressure, minimizing exposed filament to the environment and allowing for controlled tension management, using a sliding component with a bias force and a sensor to adjust the feed rate accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing slack management systems are used, then filament tension can be managed, but the systems become cumbersome, difficult to seal, and increase costs and maintenance
Solution Approach 1:
The patent extracts the slack management function from complex external systems and integrates it directly into the print head structure. The movable component with passage is incorporated within the print head assembly, eliminating the need for separate cumbersome slack management systems while maintaining filament tension control capability.
Solution Approach 2:
The patent merges the slack management mechanism with the print head structure. The movable component that adjusts filament path length is integrated into the print head assembly, combining multiple functions (printing and slack management) into a single unified structure, thereby reducing overall system complexity.
2Reliability
If existing slack management systems are used, then filament tension can be managed, but extensive sealing and purge gas supplies are required
Solution Approach 1:
The patent extracts the filament path adjustment function from the external environment and places it within the controlled interior of the print head. The movable component with passage is positioned inside the print head assembly, where the filament is already protected from moisture and oxidation, eliminating the need for extensive sealing and purge gas supplies.
Solution Approach 2:
The patent uses the print head structure itself as an intermediary protective barrier. By positioning the slack management mechanism within the print head, the existing heated chamber and controlled environment serve as the protective intermediary, shielding the filament from harmful environmental factors without requiring additional sealing systems.
3Force
If filament path length is adjusted, then tension on feed mechanism is reduced, but the system requires precise control mechanisms
Solution Approach 1:
The patent employs a movable component that can dynamically adjust the filament path length in response to operational conditions. The movable component with passage allows the filament path to be dynamically extended or retracted, enabling real-time tension management without requiring complex automated control systems, as the mechanical structure itself provides the adjustment 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
This solution reduces tension on the filament feed mechanism, improves print quality by minimizing filament breakage, and enhances the printing of sensitive materials by maintaining a controlled environment on the print head, reducing the need for extensive sealing and purge gas supplies.
Implementation Method 1
The sliding component may adjust a path length of the filament in response to a pressure on the filament during a printing process
Implementation Method 2
the component constructed and arranged to provide a bias force is a spring. For example, one or more springs may be coupled to one or both of the sliding component and the housing
Implementation Method 3
the component constructed and arranged to provide a bias force is a magnet positioned on the sliding component opposing a magnet positioned in the housing
Data Source
AI summary
A three-dimensional printer for the additive manufacturing of a part is provided. The printer includes a build platen, a pre-extrusion system, and a print head located downstream of the pre-extrusion system and configured to receive and deposit a filament. The print head includes a receiving section configured to receive the filament, an outlet through which the filament is deposited onto the build platen or a previously added layer of a part, a feeding mechanism constructed and arranged to feed the filament into the outlet, and a path length adjustment system positioned on the print head disposed between the pre-extrusion system and the feeding mechanism. The path length adjustment system constructed and arranged to create slack in the filament being delivered from the pre-extrusion system. Path length adjustment devices incorporating sliding components and flexure components are also disclosed.