Replaceable Continuous Fiber Print Head for Nozzle Wear Control
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Solution Overview
Problem
Existing nozzle wear during continuous fiber reinforced resin matrix composite printing leads to extrusion deformation and layer thickness inconsistencies, particularly in large-scale additive manufacturing, necessitating frequent device resets and reducing forming efficiency.
Innovation Solution
A nozzle-replaceable printing head with a modular design featuring a rotating nozzle support plate, adjustable wire feeding, and integrated shearing module, allowing for on-line nozzle replacement and standardized clamping adjustments to maintain consistent printing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous fiber reinforced composite printing is performed for long-term additive manufacturing of large members, then productivity is improved, but nozzle wear increases causing extrusion deformation and layer thickness inconsistencies
Solution Approach 1:
The patent implements a rotatable nozzle support plate that allows dynamic switching between multiple nozzles during the printing process. When one nozzle wears out, the system can rotate to use another nozzle, maintaining consistent printing quality without stopping production. This dynamic replacement mechanism resolves the contradiction between continuous printing productivity and nozzle wear-related quality degradation.
2Reliability
If the device is stopped to replace a worn nozzle, then printing quality is maintained, but productivity decreases due to required device reset
Solution Approach 1:
The patent pre-installs multiple nozzles on the rotatable support plate before the printing process begins. This preliminary preparation allows for quick nozzle switching without requiring device reset or lengthy replacement procedures. The system can seamlessly transition between nozzles, maintaining both high printing quality and productivity.
3Ease of manufacture
If conventional wire feeding structures with spring dampers and bolt adjustments are used, then ease of manufacture is improved, but manufacturing precision decreases due to reliance on experiential hand feel without clear adjustment indications
Solution Approach 1:
The patent replaces the conventional spring-based mechanical wire feeding structure with a gear-driven wire feeding mechanism. This substitution eliminates the need for experiential hand feel adjustments by providing precise, controllable wire feeding through gear engagement. The new mechanism offers clear adjustment indications and consistent clamping states, improving manufacturing precision while maintaining ease of manufacture.
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 high-quality forming of large parts by minimizing nozzle wear-related defects through standardized clamping and online nozzle replacement, ensuring continuous fiber reinforced composite additive manufacturing efficiency.
Implementation Method 1
a heating coil, and a nozzle module located at a bottom of the structure
Implementation Method 2
a heat dissipation sleeve, a throat pipe, a heating coil
Data Source
AI summary
A nozzle-replaceable printing head for continuous fiber printing and a printing method are provided. The printing head includes a fixed bracket, a wire feeding module located at an upper part of the structure, an upper guide pipe, a shearing module located at a middle part of the structure, a lower guide pipe, a heat dissipation sleeve, a throat pipe, a heating coil, and a nozzle module located at a bottom of the structure, where a continuous fiber reinforced thermoplastic resin matrix pre-impregnated composite wire coaxially penetrates through the other side of the printing head from top to bottom and is fed for printing. An adjustment groove with scales is configured to standardize adjustment on clamping and feeding states of pre-impregnated composite wires of different specifications.