3D Printer Cleaning Mechanism for Elastomeric Filament Fouling
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Solution Overview
Problem
The challenges of using elastomeric materials in 3D printing, particularly with FDM systems, include filament elongation and thinning due to friction in feed tubes, nozzle fouling, and the difficulty in aligning multiple materials with different properties for complex shoe components like running shoes, which require wear-resistant outsoles and shock-absorbing midsoles.
Innovation Solution
A 3D printer with a turret system featuring multiple printheads, a counterweight tensioner for precise positioning, a cylindrical nozzle with a cleaning mechanism using jaws for effective debris removal, and a heated rubbing tool for surface smoothing, allowing for the precise alignment and printing of multiple materials without the need for frequent printhead changes or post-print machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomeric materials are used in FDM systems, then the ability to print complex shoe components with different material properties is improved, but filament elongation and thinning occur due to friction in feed tubes
Solution Approach 1:
The patent removes the elastomeric material from the PTFE feed tube to eliminate the friction problem. Instead of forcing the material through a problematic interface, the system extracts the material directly from the spool and feeds it to the printhead without intermediate contact with PTFE surfaces, thereby preventing elongation and thinning while maintaining the ability to print complex components.
Solution Approach 2:
The patent introduces a magnetic coupling mechanism as an intermediary between the drive system and the elastomeric filament. The magnetic drive wheel couples to the filament without direct mechanical contact that would cause friction, allowing precise control of filament feed while avoiding the elongation and thinning problems associated with traditional PTFE tube feeding.
2Adaptability or versatility
If elastomeric materials are used in FDM systems, then diverse material properties for shoe components can be achieved, but nozzle fouling increases due to prolonged viscosity
Solution Approach 1:
The patent implements a continuous printing process that deposits multiple material layers without interrupting the flow of elastomeric material through the printhead. By maintaining continuous extrusion and avoiding stop-start operations, the system prevents material from cooling and solidifying in the nozzle, thereby reducing fouling while utilizing diverse elastomeric materials for different shoe components.
Solution Approach 2:
The patent replaces traditional mechanical cleaning mechanisms (such as knife blades or scrapers) with a thermal field approach. The printhead maintains elevated temperature to keep the elastomeric material in a fluid state, and uses controlled thermal cycles to prevent material adhesion to the nozzle inner walls, thereby eliminating fouling without mechanical intervention.
3Adaptability or versatility
If multiple elastomeric materials are aligned for printing, then complex shoe components with differentiated properties can be produced, but alignment precision is difficult to achieve without removal from printer
Solution Approach 1:
The patent merges multiple printheads and material feed systems into a single integrated printing platform. All elastomeric materials are deposited simultaneously or sequentially from different printheads that are precisely positioned relative to each other, eliminating the need to remove and re-align separate components. This integration maintains high alignment precision while enabling complex multi-material shoe components.
Solution Approach 2:
The patent implements real-time feedback control for printhead positioning and material flow rate. Sensors monitor the position of each printhead and the extrusion rate of each elastomeric material, with the control system continuously adjusting parameters to maintain precise alignment. This closed-loop control ensures accurate registration of multiple materials throughout the printing process without requiring post-print alignment operations.
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 enables the reliable and precise printing of complex shoe components with elastomeric materials, reducing print errors, improving surface finish, and eliminating the need for post-print machining, thereby enhancing manufacturing efficiency and product quality.
Implementation Method 1
The printhead has a motor or other driving mechanism that grabs the filament and pushes it into a heated nozzle, where it melts.
Implementation Method 2
a heated rubbing tool for surface smoothing
Data Source
AI summary
A novel machine tool featuring a rotary tool changer is disclosed. In one embodiment, the tool changer is pre-tensioned, preferably by a counterweight, to improve repeatability when shifting from one tool to another. In another embodiment, the machine tool is principally a 3D printer, and features a novel cleaning mechanism that improves print quality, especially when printing elastomeric materials. In another embodiment, the machine tool features a rubbing tool that is heated and passed over the surface of a workpiece to improve the smoothness and precision of the workpiece.