Rotatable Extruder Nozzle with Variable Orifice for 3D Printing
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Solution Overview
Problem
Current 3D printing systems are slow and inefficient due to the limitations of nozzle orifice size, which affects build time and detail resolution.
Innovation Solution
A multi-directional, rotatable extruder with a non-circular or variable-size nozzle orifice, controlled by a computer controller, to reduce the number of passes needed to generate a 3D object by adjusting the nozzle opening and rotation, allowing for more efficient material deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a smaller nozzle orifice is used, then detail resolution is improved, but build time increases due to more passes required
Solution Approach 1:
The nozzle orifice size is made dynamically adjustable during the printing process. The system can switch between different orifice sizes (e.g., 0.4mm for detailed features, 0.8mm for general deposition) based on the current printing requirements, allowing optimization of both resolution and build time throughout the build process
Solution Approach 2:
The system changes the physical parameter of orifice size to optimize printing performance. By having multiple orifice sizes available and selectable, the system can adapt the deposition width to match the required detail level for different regions of the printed object, reducing the number of passes needed for each feature type
2Productivity
If a larger nozzle orifice is used, then build time is reduced by depositing material faster, but detail resolution deteriorates
Solution Approach 1:
The system dynamically selects appropriate orifice sizes based on real-time printing requirements. When printing detailed features, smaller orifices are engaged; when printing larger areas, larger orifices are used, optimizing both speed and quality for different stages of the build
Solution Approach 2:
The nozzle system is segmented into multiple orifice options (e.g., 0.4mm, 0.6mm, 0.8mm). This segmentation allows the system to choose the appropriate level of detail deposition for each specific feature being printed, rather than being constrained to a single fixed orifice size
3Ease of manufacture
If a fixed circular orifice is used, then manufacturing is simple, but the number of passes required increases for efficient material deposition
Solution Approach 1:
The nozzle system transitions from a fixed orifice to a dynamically selectable orifice system. The ability to change orifice size and shape allows optimization of material deposition patterns for different geometries, reducing the number of passes required while maintaining manufacturing feasibility
Solution Approach 2:
The nozzle system is designed to perform multiple functions by incorporating various orifice types and sizes in a single nozzle assembly. This multi-functional design allows the same nozzle to handle both detailed feature deposition and rapid material buildup, eliminating the need for multiple specialized nozzles
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 enhances the speed and detail resolution of 3D printing by allowing for wider nozzle orifices to deposit material in fewer passes, improving the overall efficiency and precision of the 3D printing process.
Implementation Method 1
a heater configured to heat the material to be discharged by the extruder
Implementation Method 2
the opening configured to discharge material... along a plurality of paths... for generating a three-dimensional object
Data Source
AI summary
An extruder for a three-dimensional additive printer can be used to receive and dispense material. The extruder can include a number of different components including a nozzle with an adjustable opening configured to discharge material. The nozzle can be configured to be moved and rotated so as to align the adjustable opening with a plurality of paths along which the material is configured to be deposited for generating a three-dimensional object. The adjustable opening can comprise a first orifice and an obstruction member configured to move with respect to the first orifice. The position of the obstruction member can adjust the size of the opening area of the adjustable opening.