Construction 3D Printer Material Feeding System
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Solution Overview
Problem
Existing 3D printing technologies face issues with inefficient mixing and feeding of construction materials, inability to control mixing and feeding speeds separately, and difficulties in maintaining the printer due to solidification of residual mix, leading to suboptimal printing quality and increased risk of equipment failure.
Innovation Solution
A system comprising a housing with two interconnected cavities for mixing and feeding, featuring a rotating mixing roller with blades or pins and a feeding roller as a gerotor pair rotor, allowing separate speed control and preventing leakage, along with a cyclone for dry powder feeding and a replaceable nozzle for shaping the extruded mixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single auger is used for mixing and feeding material, then the device structure is simple, but the mixing efficiency is low and mixing time is excessive
Solution Approach 1:
The single auger is divided into two separate functional components: a mixing roller with mixing elements and a feeding roller with feeding elements. This segmentation allows independent optimization of mixing and feeding functions, improving mixing efficiency while maintaining reasonable device complexity through specialized components.
Solution Approach 2:
The mixing roller is designed to perform both mixing and feeding functions through its dual elements (mixing elements and feeding elements), allowing one component to serve multiple purposes and reducing the need for separate dedicated components for each function.
2Device complexity
If a single auger performs both mixing and feeding, then the device is simpler, but the speeds of mixing and feeding cannot be adjusted independently
Solution Approach 1:
The single drive system is segmented into two independent drives: one for the mixing roller and another for the feeding roller. This allows separate speed control and adjustment of each function, providing adaptability for different material types and printing requirements while maintaining a relatively simple overall device structure.
Solution Approach 2:
The system transitions from a static, single-speed drive to a dynamic system with independently controllable speeds for mixing and feeding. This enables real-time adjustment of operational parameters to optimize performance for different materials and printing conditions.
3Device complexity
If the mixture is fed in dissolved form through long hoses, then the feeding system is simpler, but the mixture consistency is unsuitable and cleaning is difficult
Solution Approach 1:
The mixing function is extracted from the remote mixing station and integrated directly into the print head assembly. This eliminates the need for long hoses and external mixing equipment, ensuring proper mixture consistency is maintained throughout the feeding process while simplifying the overall feeding system architecture.
Solution Approach 2:
The mixture is prepared and mixed immediately before extrusion within the print head, rather than being prepared in advance and transported through hoses. This preliminary action ensures the mixture maintains optimal consistency for printing while reducing the complexity of the feeding system.
4Duration of action of stationary object
If residual mix solidifies inside the feed system, then the device continues operating, but equipment failure risk increases
Solution Approach 1:
The mixing function is extracted from the feed system and placed in a dedicated mixing cavity within the print head. This separation allows the feed system to be designed with easy-access cleaning features and enables quick removal of residual material, maintaining continuous operation capability while reducing equipment failure risk from solidified mix.
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 efficient mixing and controlled feeding of the mixture, allowing for faster and higher-quality printing with more viscous materials that harden quickly and maintain their shape better, reducing the risk of equipment failure and improving layer thickness and surface quality.
Implementation Method 1
a mixing roller (4) in the mixing cavity (2), the mixing roller (4) being designed with a possibility to rotate using its own drive (6)
Implementation Method 2
a feeding roller (5) in the feeding cavity (3)... the feeding element (15) can be made in the form of feed vanes or at least two auger flights, which ensures the capture of the ready mixture from the mixing cavity (2) and its feeding through the channel (13) into the feeding cavity (3)
Implementation Method 3
A cyclone (9) for supplying dry powder mixture is connected to the mixing cavity (2)
Implementation Method 4
there is a hollow alternative nozzle (10) with its own drive (8), which rotates the nozzle through... The mixture, passing through the nozzle, takes a shape determined by the geometry of this nozzle
Data Source
AI summary
A system for preparing and feeding the material of a construction 3D printer comprises a housing including two cavities connected by a finished mixture feeding channel: a mixing cavity with a mixing roller and a feeding cavity with a feeding roller. A mixing roller is designed to rotate using its own drive; it is a cylinder with two functional elements installed on it: a mixing element and a feeding element. A feeding roller is designed to rotate using its own drive; and it is a rotor of the gerotor pair; and the axes of the mixing and feeding rollers are mutually perpendicular. A dry powder mixture feeding cyclone is connected to the mixing cavity, which is connected to the dry mixture feed channel and the liquid feed channel, an alternative nozzle with its own drive is installed at the outlet of the feed cavity.