Rotatable Nozzle Correction for Consistent 3D Print Thickness
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Solution Overview
Problem
Current 3D printing technologies, such as FDM, face challenges in maintaining consistent material thickness when depositing on surfaces with varying angles, leading to potential delamination and uneven object quality.
Innovation Solution
A system with a rotatable nozzle and movable support, actuated via a connector, applies a correction factor to adjust the nozzle's path based on the angle with the deposition surface, ensuring consistent thickness by changing the distance from the surface when moving towards or away from an acute angle, and includes a softening zone and forming rollers to enhance material flexibility and deposition precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the nozzle deposits material at a fixed angle relative to the deposition surface, then the system structure is simple, but the deposited material thickness varies on surfaces with varying angles
Solution Approach 1:
The nozzle is made dynamically adjustable through a connector mechanism that can change the angular orientation of the nozzle axis relative to the deposition surface. This dynamic adjustment allows the system to adapt to varying surface angles and maintain consistent material thickness, resolving the contradiction between manufacturing precision and device complexity by introducing controlled mobility where needed.
Solution Approach 2:
The system changes the angular parameter of the nozzle orientation based on the deposition surface angle. By adjusting the nozzle angle dynamically, the system maintains optimal deposition geometry across varying surface orientations, ensuring consistent material thickness without requiring complete system redesign.
2Manufacturing precision
If the nozzle moves closer to the surface when depositing on acute angles, then material thickness consistency is improved, but the risk of nozzle contact with the object increases
Solution Approach 1:
The connector mechanism provides dynamic adjustment capability, allowing the nozzle to change its angular orientation in real-time based on the deposition surface geometry. This dynamic adaptability enables the system to maintain optimal deposition distance and angle, improving material thickness consistency while the control system monitors and adjusts parameters to prevent nozzle collision with the object.
Solution Approach 2:
The system employs feedback control to monitor the nozzle position, angle, and distance from the deposition surface. Based on this feedback, the controller adjusts the nozzle orientation and movement parameters to maintain consistent material thickness while preventing collision, thus resolving the contradiction between manufacturing precision and reliability.
3Ease of manufacture
If the nozzle axis remains perpendicular to the movable support, then the actuation mechanism is simple, but the deposition quality on sloped surfaces deteriorates
Solution Approach 1:
The connector mechanism introduces controlled dynamics to the nozzle orientation, allowing it to adapt its angular position relative to the movable support based on the deposition surface geometry. This dynamic capability enables high-quality deposition on sloped surfaces while maintaining relative simplicity in the actuation mechanism through targeted mobility.
Solution Approach 2:
The system changes the angular parameter of the nozzle orientation relative to the movable support according to the deposition surface angle. By adjusting this parameter dynamically, the system maintains optimal deposition geometry on sloped surfaces without requiring complete redesign of the actuation mechanism.
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 creation of objects with improved resistance to delamination and consistent thickness across varying surface angles, enhancing the reliability and quality of 3D printed components.
Implementation Method 1
The softening zone can be configured to apply heat to the feedstock material passing therethrough
Implementation Method 2
The filament is liquefied before or as it passes through the constriction in the nozzle, and the feed pressure causes material to be extruded
Data Source
AI summary
A system for fabricating an object includes an extruder for one or more deposition materials having at least one nozzle and a movable support for the nozzle. The nozzle has a nozzle axis and is rotatably attached to the movable support via a connector that is actuatable relative to the movable support to change an angular orientation of the nozzle axis, thus varying an angle between the nozzle axis and a deposition surface. The system also includes a controller that can apply a correction factor calculated for a path of the nozzle when an acute angle is formed between the nozzle axis and the deposition surface, the correction factor for moving toward the acute angle being different from that when moving away from it. The correction factor removes differences in thickness of the deposited material caused by variations in the angle formed between the nozzle axis and the deposition surface.