Rotatable Extruder Module for 3D Composite Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printing technologies for composite materials are limited by their inability to achieve true 3D fabrication, resulting in low fiber alignment with stress directions and high porosity, and are often labor-intensive, expensive, and require large, costly machines due to gantry-style approaches, which restrict scalability and flexibility.
Innovation Solution
A 3D printing machine with a rotatable extruder module and end-effector that allows for independent orientation of the nozzle assembly, enabling the extrusion of filaments in various directions without rotating the entire machine, combined with a robotic system for enhanced flexibility and dexterity, and the use of laser optics for improved material flow and reduced porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gantry style approach is used for 3D printing, then the machine can build layers in the x-y plane, but the machine size and cost increase directly with part size, reducing scalability and flexibility
Solution Approach 1:
The patent replaces the static gantry structure with a dynamic robotic system featuring a movable base that can reposition the end-effector to different locations within or around the cell. The robotic arm provides multiple degrees of freedom, allowing the same machine to fabricate parts of varying sizes without requiring proportional increases in machine footprint.
Solution Approach 2:
The robotic system serves multiple functions: it can fabricate parts of different sizes, reposition itself for different locations, and accommodate multiple robot poses. This multi-functionality allows a single machine to handle diverse part sizes and configurations, eliminating the need for different machine sizes for different part dimensions.
2Ease of manufacture
If traditional 2.5D additive manufacturing is used where the machine builds layer by layer in the x-y plane, then the fabrication process is simplified, but true 3D fabrication capability is lost, limiting structural performance
Solution Approach 1:
The patent transitions from 2.5D layer-by-layer fabrication to true 3D fabrication by utilizing the robotic system's ability to move in three dimensions concurrently. The end-effector can extrude material in any spatial direction, allowing fibers to be aligned with stress directions in three-dimensional space rather than being constrained to planar layers.
Solution Approach 2:
The robotic system provides dynamic positioning capability with multiple degrees of freedom, enabling the end-effector to achieve any position and orientation in 3D space. This dynamic capability allows concurrent building in x, y, and z directions,实现ing true 3D fabrication with optimized fiber alignment for structural performance.
3Adaptability or versatility
If the entire machine is rotated to change extrusion direction, then all extrusion directions can be achieved, but machine wear increases and operational complexity increases
Solution Approach 1:
The patent separates the rotation function from the entire machine by introducing an independent rotatable extruder module at the end-effector. Only the nozzle assembly needs to rotate to change extrusion direction, while the rest of the robotic system remains stationary. This segmentation reduces wear on rotation mechanisms and simplifies operational control.
Solution Approach 2:
The rotatable extruder module adds a rotational degree of freedom at the end-effector, enabling the nozzle to orient in any direction independently of the robotic arm's position. This local rotational capability provides full extrusion direction versatility without requiring rotation of the entire machine system.
4Productivity
If known composite additive manufacturing approaches are used, then 3D printing capability is provided, but fiber volume is low, porosity is high, and structural performance is limited
Solution Approach 1:
The patent replaces traditional mechanical extrusion systems with a robotic system that provides precise control over material deposition. The robotic arm's multiple degrees of freedom enable accurate positioning and orientation of the extruded material, improving fiber alignment and reducing porosity. The system can accommodate various filament types including continuous fibers, achieving higher fiber volumes and better structural performance.
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 solution enables the fabrication of high-performance 3D integrated composite structures with improved fiber alignment, reduced porosity, and increased scalability and flexibility, allowing for the production of complex parts with enhanced structural performance and reduced machine wear.
Implementation Method 1
a FFF process provides a stock material to a heated nozzle, where it is extruded therefrom to be laid down layer by layer to build up a desired product, and where the molten polymer or fiber reinforced polymer material immediately begins to harden once it is extruded from the nozzle
Implementation Method 2
the molten polymer or fiber reinforced polymer material immediately begins to harden once it is extruded from the nozzle
Implementation Method 3
the use of laser optics for improved material flow and reduced porosity
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A printing machine for fabricating high performance 3D integrated composite structures. The machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the end joint. The end-effector includes at least one extruder module for extruding the extrudable material and a rotary assembly, where the extruder module includes a nozzle assembly for extruding heated material out of the end-effector. The extruder module is mounted to the rotary assembly and the rotary assembly is rotatable so as to rotate the nozzle assembly relative to the part without rotating the end-effector.