Rotatable 3D Printer Extruder with Variable Orifice
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Solution Overview
Problem
Current 3D printing systems are slow and inefficient due to the limitations of traditional extruder nozzles, which require multiple passes to deposit material and restrict the level of detail achievable, largely because of their fixed circular orifice size and lack of precise control over deposition paths.
Innovation Solution
A multidirectional, rotatable extruder with a non-circular orifice and variable-size opening, controlled by a computer controller, allowing for precise material deposition and reduced number of passes needed to generate a 3D object, utilizing a nozzle with an adjustable opening and rotation control to align the orifice with desired paths for efficient material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional extruder with fixed circular orifice is used, then the device structure is simple, but the printing speed is slow and multiple passes are required
Solution Approach 1:
The patent applies dynamics by making the orifice size adjustable rather than fixed. The extruder nozzle includes a variable orifice that can change its opening size during operation, allowing the system to adapt between different printing requirements. This dynamic adjustment enables faster material deposition when larger openings are used, while maintaining the capability for detailed work with smaller openings, thus improving printing speed without excessive complexity increase.
Solution Approach 2:
The patent changes the parameter of orifice size from fixed to variable. By implementing a variable orifice mechanism that can adjust its opening area, the system can optimize material flow rate according to different printing stages and requirements. This parameter change allows single-pass printing in certain scenarios, directly addressing the productivity issue while keeping the structural complexity manageable through controlled parameter variation.
2Manufacturing precision
If a fixed circular orifice is used, then the device is easy to manufacture, but the detail resolution is limited
Solution Approach 1:
The variable orifice mechanism allows the system to dynamically adjust the opening size to match the required detail resolution. For high-detail areas, the orifice can be positioned to provide smaller effective openings, while for broader areas, larger openings can be used. This dynamic adaptability enables high manufacturing precision without requiring multiple specialized nozzles, thus balancing detail resolution with manufacturing complexity.
Solution Approach 2:
The variable orifice nozzle serves multiple functions that would traditionally require different fixed nozzles. By incorporating an adjustable mechanism, a single nozzle design can provide various orifice sizes and shapes, enabling it to handle both fine detail work and broader material deposition tasks. This multi-functionality improves detail resolution capabilities while avoiding the need to manufacture and manage multiple specialized nozzle components.
3Manufacturing precision
If multiple passes are used for material deposition, then complete coverage is achieved, but the printing time increases
Solution Approach 1:
The variable orifice mechanism allows optimization of material deposition parameters for different printing scenarios. By adjusting the orifice size and shape according to the specific requirements of each printing area, the system can achieve complete material coverage in single-pass operations where appropriate, eliminating the time loss associated with multiple passes while maintaining high-quality coverage through parameter optimization.
Solution Approach 2:
The ability to adjust orifice parameters continuously during printing enables the system to maintain optimal material deposition rates throughout the printing process. This continuity allows the extruder to adapt to varying requirements without stopping for reconfiguration or requiring multiple passes, thereby reducing printing time while ensuring complete and quality material coverage through sustained useful action.
Data Source
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AI summary
An extruder or a dual head 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 or two nozzles with at least one having an adjustable opening configured to discharge material. The nozzle or adjustable opening 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.