3D Printing Head Assembly for Rotating Substrate

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Solution Overview

Problem

Conventional 3D printing techniques suffer from low efficiency, resolution, and throughput due to layer-by-layer printing on a planar surface, making them unsuitable for industrial production, especially when printing multiple objects simultaneously.

Innovation Solution

A 3D printing process using a print head assembly with multiple units arranged along an axis, allowing for simultaneous layer-by-layer printing on a rotating substrate, with print head units moving radially to maximize utilization, employing fusible and non-fusible materials for efficient object construction and support, and incorporating a conveyor system for continuous printing or discrete steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If layer-by-layer printing on a planar surface using nozzles arranged in a plane is used, then printing resolution can be maintained, but printing efficiency and throughput are low

Engineering Contradiction:

Improveprinting efficiencyVSAvoidprinting time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent transitions from planar arrangement of nozzles to a three-dimensional arrangement where print head units are positioned at different locations along an axis perpendicular to the substrate. This dimensional change allows multiple nozzles to print simultaneously on different layers, dramatically increasing throughput while maintaining resolution through precise positional control.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The printing system is divided into multiple print head units, each with its own nozzles, arranged at different positions along the vertical axis. Each print head unit can independently deposit material, allowing parallel processing of different layers and significantly improving overall printing efficiency.

Inventive Principle:

Principle #1Segmentation

2Productivity

If multiple print head units are arranged at different locations along an axis, then printing throughput increases, but system complexity increases

Engineering Contradiction:

Improveprinting throughputVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple print head units are designed with identical or similar nozzle configurations, allowing them to perform the same printing function simultaneously at different vertical positions. This modular universality simplifies the overall system design while achieving high throughput through parallel operation of standardized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If print head units are moved radially to maximize utilization, then printing efficiency increases, but control precision requirements increase

Engineering Contradiction:

Improveprint head utilizationVSAvoidpositioning accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system incorporates feedback mechanisms to monitor and adjust the radial positions of print head units in real-time, ensuring that each nozzle remains precisely positioned relative to its target location on the substrate. This feedback control maintains manufacturing precision while enabling dynamic optimization of print head utilization.

Inventive Principle:

Principle #23Feedback

4Speed

If continuous printing is performed while rotating the substrate, then printing speed increases, but maintaining resolution becomes more challenging

Engineering Contradiction:

Improveprinting speedVSAvoidprinting resolution

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The substrate rotation is implemented to enable continuous printing without interruption, allowing the build plate to constantly present new surfaces to the fixed print head units. This continuous action maintains high printing speed while the controlled rotation ensures that material is deposited precisely where needed, preserving resolution.

Inventive Principle:

Principle #20Continuity of useful action

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 approach enables high-efficiency, high-resolution printing of multiple objects with increased throughput, optimizing print head utilization and reducing production time, making it suitable for industrial production lines.

Implementation Method 1

successively depositing layers of printing/forming materials over a rotating substrate

Methodology Applied

Scientific EffectLayer-by-layer deposition: Deposition (physical)

Implementation Method 2

fusible materials (i.e., capable of being fused to a previous layer, or to the substrate)

Methodology Applied

Scientific EffectFusing: Melting

Data Source

PatentUS10583645B2System and method for printing three-dimensional objects

Publication Date: 2020.03.10 VELOX PUREDIGITAL LTD

AI summary

A layer-by-layer three dimensional printing technique for printing on outer surfaces of a plurality of substrate elements passing through a printing route/zone while being rotated thereinside about a printing axis. At least one array of printing head units is used to define at least one printing route along the printing axis, where the at least one printing route is a substantially linear segment of a closed loop lane along which the objects are progressing. The print head units being configured for movement along radial axes, or one or more axes substantially perpendicular, to the printing axis, to allow layer-by-layer printing of said three-dimensional objects over said substrate elements while being rotated in said printing route.