3D Printing Nozzle Texturing Member for Inter-Layer Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing techniques, such as 3-D printing, often result in articles with inferior mechanical strength due to poor adhesion between layers, which is exacerbated in multi-material prints and techniques like powder sintering and Fused Deposition Modeling (FDM), where inter-layer adhesion is weak.
Innovation Solution
A printing head with a nozzle featuring a texturing member that creates protrusions with a polygonal outline and corners less than 90 degrees to increase the surface area between layers, allowing for enhanced interlocking and adhesion, and optionally a spraying member to further increase the surface area with granular materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard printing materials and smooth nozzle outlets are used, then the printing process is simple and fast, but the inter-layer adhesion is weak resulting in inferior mechanical strength
Solution Approach 1:
The nozzle outlet is designed with a polygonal cross-section featuring curved corners with angles less than 90 degrees. These curved geometric features create protrusions in the deposited layer that increase surface area and provide mechanical interlocking with subsequent layers, thereby improving inter-layer adhesion without requiring complex additional components
Solution Approach 2:
The invention changes the geometric parameters of the nozzle outlet by introducing specific corner angles (less than 90 degrees) and polygonal shapes. This parameter modification transforms the smooth outlet into one that naturally forms protrusions during material deposition, enhancing adhesion through geometric design rather than structural complexity
2Strength
If coating filaments with additives is done to improve inter-layer adhesion, then adhesion improves, but the composition of printing material is altered which may be undesirable
Solution Approach 1:
The invention extracts the adhesion-enhancing function from the material composition itself and transfers it to the nozzle geometry. By removing the need for compositional modifications and focusing solely on geometric design, the original material composition integrity is preserved while still achieving improved inter-layer adhesion
Solution Approach 2:
The polygonal nozzle outlet with curved corners acts as an intermediary between the printing material and the deposited layer. This geometric intermediary creates the protrusions that enhance adhesion, serving as a mediator that improves bonding without requiring changes to the material composition
3Strength
If layers are deposited smoothly without texturing, then the printing process is fast and simple, but the surface area between layers is insufficient resulting in weak adhesion
Solution Approach 1:
The protrusions are formed preliminarily during the deposition process itself through the pre-designed polygonal nozzle geometry with curved corners. This preliminary formation of adhesion-enhancing features occurs as part of the normal printing process, avoiding the need for separate texturing steps that would reduce printing speed
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
The solution significantly improves the mechanical strength of 3-D printed articles by increasing inter-layer adhesion without altering the composition of standard printing materials, allowing for stronger and more durable prints.
Implementation Method 1
The outlet is shaped to form protrusions extending from a main surface of the layer for interlocking with a subsequent layer
Implementation Method 2
The texturing member provides the outlet with a polygonal outline, and the polygonal outline comprises a plurality of corners having an angle less than 90 degrees. Such a printing head increases the surface area between adjacent layers of an article printed in this manner, which increases the adhesive strength between layers
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A printing head (100) for a 3-D printing device is disclosed that comprises a nozzle (110) arranged to print a layer (140) of a printing material on a receiving surface (130) and a texturing member (120) arranged to texture the layer or the receiving surface during printing of said layer. The nozzle comprises an outlet including the texturing member (120) and the outlet is shaped to form protrusions (145) extending from a main surface of the layer (140) for interlocking with a subsequent layer. The texturing member ensures that contacting layers formed with the printing head exhibit improved adhesion due to the increased contact surface area between the layers. This yields stronger 3-D articles printed in this manner. A printing apparatus including the printing head, a printing method and an article printed in accordance with the printing method are also disclosed.