Rotary Platen 3D Printer with Helical Ingot Deposition
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Solution Overview
Problem
Current three-dimensional object fabrication techniques, such as FDM, face challenges with speed, cost, and reliability due to limited deposit size, precise temperature control requirements, moisture issues, and the need for sacrificial materials, leading to increased time and expense.
Innovation Solution
A system that uses a monolithic helically-threaded plastic ingot with a melt impeller and extrusion nozzle for efficient plastic deposition, allowing for larger instantaneous supplies and variable layer thickness, along with a modular assembly zone and integrated welding process to eliminate the need for sacrificial support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If FDM deposits tiny amounts of plastic individually to build objects from the ground up, then manufacturing precision is improved, but productivity deteriorates due to hours required to produce even simple objects
Solution Approach 1:
The invention segments the plastic supply into discrete, pre-measured pellets rather than continuous filament, allowing for precise control of material quantity while enabling faster deposition rates. Each pellet represents a discrete unit of material that can be rapidly extruded without the continuous temperature control constraints of traditional FDM
Solution Approach 2:
The invention changes the physical state and delivery mechanism of plastic from continuous heated filament to discrete cooled pellets. This parameter change allows the system to operate at higher speeds while maintaining precision, as the pellets are extruded in a controlled manner without requiring continuous temperature control during deposition
2Manufacturing precision
If FDM uses small deposit sizes with strict temperature control, then manufacturing precision is improved, but device complexity increases due to precise temperature control requirements
Solution Approach 1:
The plastic is pre-cooled and formed into discrete pellets before deposition. This preliminary action removes the need for continuous temperature control during the deposition process, as the material is already in a controlled state. The extrusion process simply transfers the pre-formed pellets without requiring active temperature regulation
Solution Approach 2:
The invention replaces the thermal field-based control mechanism of FDM with a mechanical field-based approach. Instead of controlling deposit size through temperature, the system uses mechanical extrusion of pre-formed pellets to control material quantity. This substitution eliminates the complex temperature control system while maintaining precision
3Reliability
If FDM requires desiccation of plastic supply to prevent moisture-induced fusion failure, then reliability is improved, but loss of time increases due to drying requirements
Solution Approach 1:
The invention uses disposable, pre-formed plastic pellets that are extruded and deposited without requiring preservation or desiccation. The pellets are designed to be used in their as-extruded state, eliminating the time-consuming drying process required by traditional FDM materials. This approach maintains reliability by ensuring consistent material properties without moisture absorption
4Manufacturing precision
If FDM uses sacrificial material for overhang support, then manufacturing precision is improved, but loss of substance increases due to additional material requirements
Solution Approach 1:
The invention extracts and eliminates the sacrificial support material from the fabrication process. By using discrete extruded pellets, the system can deposit material directly onto overhangs without requiring additional support structures. The pellets are deposited in a controlled manner that allows overhangs to be formed as part of the final object, removing the need for sacrificial material entirely
5Ease of operation
If FDM uses spools for plastic supply, then ease of operation is improved, but loss of substance increases due to high cost and inability to reuse partially consumed spools
Solution Approach 1:
The invention segments the plastic supply into discrete, countable pellets rather than continuous spool material. This segmentation allows for precise tracking and management of material consumption, enabling reuse of partially consumed material through automated pellet transfer systems. The discrete nature of pellets facilitates more efficient material management compared to traditional spool-based systems
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 faster, more reliable, and cost-effective fabrication of complex objects by reducing the need for precise temperature control, minimizing waste, and allowing for unsupported overhangs, thereby improving production efficiency and reducing material costs.
Implementation Method 1
a melt impeller and extrusion nozzle for efficient plastic deposition
Implementation Method 2
monolithic helically-threaded plastic ingot
Data Source
AI summary
A three-dimensional printer to fabricate three dimensional objects using a rotary build surface platen. This architecture achieves high space efficiency, and rigidity for precision. The apparatus size can be very small relative to the objects it can build. The 3D printer can also actively shape the side profile of a layer for greater fidelity with the ideal input geometry. The profile can be shaped through subtraction of material, or by constraining the material while it is deposited.