Rotatable 3D Print Head for High Throughput and Low Complexity
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Solution Overview
Problem
Conventional 3D printing processes using multi-nozzle print heads are complex and costly, with high operating expenses due to the need for technical complexity and maintenance, despite achieving increased material throughput, which often compromises economic efficiency.
Innovation Solution
A method utilizing a print head with multiple extrusion openings aligned at a fixed angle, allowing for directional changes in material web width and discharge rate without rotating the print head, enabling flexible and efficient printing without the need for complex rotation, thus reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rotary multi-nozzle printing heads are used to increase material throughput, then productivity is improved, but device complexity and operating costs increase significantly
Solution Approach 1:
The patent applies the Dynamics principle by making the nozzle array rotatable relative to the build platform. The nozzle array can rotate during the printing process to change the orientation of the nozzles, enabling flexible adjustment of nozzle spacing and printing directions without requiring multiple fixed nozzle arrays. This dynamic configuration allows the system to adapt to different printing requirements while maintaining a compact structure.
Solution Approach 2:
The patent implements Universality by designing a single nozzle array that can serve multiple functions through rotation. The same nozzle array can be oriented at different angles to print in various directions, effectively replacing the need for multiple dedicated nozzle arrays for different printing orientations. This multi-functional design reduces overall device complexity while maintaining high productivity.
2Productivity
If rotary multi-nozzle printing heads are used to increase material throughput, then productivity is improved, but operating costs increase significantly
Solution Approach 1:
The rotatable nozzle array enables dynamic adjustment of printing parameters during operation, allowing the system to optimize material deposition rates and reduce waste. The ability to rotate the nozzle array facilitates continuous printing without requiring frequent stops for repositioning, thereby reducing operating costs while maintaining high productivity.
Solution Approach 2:
The patent utilizes Parameter changes by varying the rotational position of the nozzle array to optimize printing parameters such as nozzle-to-surface distance, scanning speed, and material flow rate. These parameter adjustments enable the system to achieve high material throughput while minimizing energy consumption and material waste, thereby reducing operating costs.
3Device complexity
If conventional single-nozzle printing is used, then device complexity is low, but productivity and material throughput are limited
Solution Approach 1:
The patent applies Segmentation by dividing the printing function into multiple nozzles arranged in an array. Instead of using a single nozzle that deposits material sequentially, the segmented nozzle array enables parallel material deposition across multiple locations simultaneously. This segmentation dramatically increases material throughput while keeping each individual nozzle simple in design.
Solution Approach 2:
The rotatable nozzle array introduces dynamics to the otherwise simple segmented structure. By rotating the entire nozzle array, the system can dynamically adjust the printing pattern and coverage area, further enhancing productivity without significantly increasing the complexity of individual nozzle components.
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 allows for continuous and undisturbed material deposition over a wide range of travel angles, reducing the number of print head movements and production time while maintaining high material throughput, and simplifying the design and maintenance of the 3D printing device.
Implementation Method 1
The print head is designed to extrude material from one or more openings or nozzles toward the print surface during the process to create the individual layers
Data Source
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AI summary
The invention relates to an additive manufacturing method, in which an extrusion material is applied to a printing surface in multiple layers arranged on top of one another along a Z-axis using a printhead, and relative movements in an X-axis and/or a Y-axis of an X,Y axial plane extending perpendicular to the Z-axis are carried out between the printhead and the printing surface during the application. The method involves a movement-direction-dependent variation of the material output width of the extrusion material that is applied to the printing surface or one of the layers arranged thereon via one or more extrusion openings in the printhead. The invention also relates to an associated computer-implemented method for 3D printing, associated 3D printheads and an associated 3D printing device.