Rotatable Variable-Size Nozzle for Single-Pass 3D Printing
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Solution Overview
Problem
Current 3D printing systems are slow and inefficient due to the limitations of traditional nozzle orifices, which require multiple passes to fill in structures and compromise on detail and speed.
Innovation Solution
A multi-directional, rotatable extruder with a non-circular or variable-size nozzle orifice, controlled by a computer controller, that can adjust its opening to deposit material efficiently and accurately, reducing the number of passes needed to generate a 3D object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional circular nozzle orifice is used, then the printing process is simple, but multiple passes are required to fill in structures reducing speed and efficiency
Solution Approach 1:
The patent applies asymmetry by changing the nozzle orifice from a traditional circular shape to a non-circular shape (such as rectangular or polygonal). This asymmetric geometry allows the extruded material to better fill in structures in a single pass, eliminating the need for multiple passes and thereby increasing printing speed and productivity without significantly complicating the nozzle structure.
Solution Approach 2:
The patent implements dimensionality change by transitioning from a circular orifice (one-dimensional symmetry) to a non-circular orifice with multiple sides or angles. This geometric transformation enables the material to be deposited in a shape that more efficiently fills the target structure, reducing the number of passes required and improving overall printing efficiency.
2Productivity
If multiple passes are used to deposit material, then material coverage is complete, but printing time increases and efficiency decreases
Solution Approach 1:
The patent applies preliminary action by pre-shaping the nozzle orifice into a non-circular geometry that is optimized for single-pass deposition. This preliminary design consideration ensures that the material is extruded in a shape that can complete the filling operation in one pass, eliminating the need for subsequent passes and thereby reducing total printing time while maintaining complete material coverage.
3Manufacturing precision
If a fixed nozzle orifice size is used, then the device is simple, but detail quality and deposition control are compromised
Solution Approach 1:
The patent implements dynamics by incorporating an adjustable nozzle orifice that can change its opening size or shape during the printing process. This dynamic adjustment capability allows the system to optimize material deposition for different printing requirements, improving detail quality and control without requiring an overly complex fixed-geometry nozzle design.
4Speed
If a non-circular or variable-size orifice is used, then single-pass deposition is enabled improving speed, but nozzle design complexity increases
Solution Approach 1:
The patent applies asymmetry by designing the nozzle orifice with a non-circular cross-section (such as rectangular or polygonal shapes). This asymmetric geometry enables the extruded material to better conform to the target structure, allowing single-pass deposition and increasing deposition speed without requiring complex adjustment mechanisms, thus balancing speed improvement with manageable design complexity.
Data Source
AI summary
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 two nozzles, at least one having an adjustable opening configured to discharge material. The 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.