3D Printer Mixing Head with Servo-Pneumatic Nozzle for Right-Angled Corners
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Solution Overview
Problem
Existing 3D printing technologies for building structures struggle to print straight walls and right-angled corners efficiently, as they often result in rounded corners that require manual correction, and face issues with mortar jamming due to varying granulations, preventing continuous extrusion and uniform layering.
Innovation Solution
A mixing-extruding head with a servo-pneumatic system and a two-part helix within the 3D printer's container, featuring a metal inner part and rubber outer part, which prevents mortar jamming and allows for the adaptation to different granulations, enabling the printing of straight walls and right-angled corners by controlling the position and shape of the mortar exit nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If known printers extrude mortar to form walls, then walls can be constructed with automated 3D printing, but the corners become rounded instead of right-angled
Solution Approach 1:
The patent applies dynamics by making the printing head rotatable and adjustable during the extrusion process. The head can change its orientation and position dynamically to deposit mortar at precise angles, enabling right-angled corners while maintaining automated construction. This resolves the contradiction by allowing the automated system to adapt its geometry in real-time.
Solution Approach 2:
The patent changes geometric parameters of the printing system, specifically the angle and position of the extrusion nozzle. By adjusting these parameters, the system can switch between producing rounded corners and precise right-angled corners, maintaining automation while improving manufacturing precision.
2Adaptability or versatility
If mortar with different granulations is used, then the system can adapt to various building material compositions, but the mortar gets stuck in the funnel and cannot continuously proceed
Solution Approach 1:
The mixing system is designed to be dynamic and adjustable, allowing real-time modification of mixing intensity and duration based on the specific mortar composition being used. This enables the system to handle different granulations reliably without jamming, maintaining both adaptability and continuous extrusion capability.
Solution Approach 2:
The system changes operational parameters such as mixing speed, mixing time, and possibly viscosity control based on the mortar granulation being used. This allows the system to adapt to different material compositions while preventing jamming and ensuring reliable continuous extrusion.
3Manufacturing precision
If finer mortar is used to print fine layers, then higher printing precision is achieved, but the system cannot handle coarser granulations required for larger scale construction
Solution Approach 1:
The mixing system dynamically adjusts its operation based on the desired layer fineness and available mortar granulation. For fine layers, it mixes finer mortar with higher precision control; for larger scale construction, it adapts to coarser granulations. This dynamic adaptation resolves the contradiction between precision and versatility.
Solution Approach 2:
The system is designed with universal mixing and extrusion capabilities that can handle a wide range of mortar granulations. The mixing head and extrusion mechanism are configured to accommodate different material compositions while maintaining the ability to produce fine layers when needed, making the system multi-functional and adaptable to various construction requirements.
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
Enables efficient and cost-effective construction of straight walls and right-angled corners by preventing mortar jamming and ensuring uniform layering, reducing manual correction time and improving the overall building process.
Implementation Method 1
a two-part helix inside a container for mixing the suitable mortar for printing the corners and walls
Implementation Method 2
the blades being controlled by a servo-pneumatic system with computer-controlled commands (instructions) for printing right-angled corners and required wall forms
Implementation Method 3
The rubber outer part prevents the larger particles from becoming stuck in the funnel
Data Source
AI summary
A mixing-extruding head apparatus for a three-dimensional (3D) printer for building residential houses and other objects, which enables printing of right-angled corners, the apparatus comprising a container for mixing mortar, the container comprising a funnel (1), a two-part helix (6) inside the container for mixing the mortar for building said objects, wherein the two-part helix (6) is installed on a main axis (2) inside the funnel (1) and the helix (6) comprises an inner metal part (6a) and an outer rubber part (6b), and wherein the helix (6) has at least one thread (turn), and an exit nozzle (14). The bottom part of the exit nozzle (14) is on each of its sides equipped with one of four blades (17), which are controlled by a servo-pneumatic system with computer-controlled commands for building the objects, wherein each of the blades is connected to a piston moved by a pneumatic cylinder; wherein all four pneumatic cylinders are connected with four electromagnetic valves, which generate pneumatic signals.