Rotating Bent-Nozzle Extruder for Internal-Surface 3D Printing
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Solution Overview
Problem
Extrusion-based 3D printing methods face challenges in adjusting printing parameters for functionally graded properties, are slow, and struggle to print on internal surfaces of structures due to limitations in nozzle configuration and material processing.
Innovation Solution
A multi-nozzle, multi-material system using bent or curved nozzles that rotate during printing, allowing for precise control of material deposition on internal surfaces and enabling functionally graded printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single small-diameter nozzle is used to achieve high resolution and print quality, then manufacturing precision is improved, but productivity deteriorates due to slow printing process
Solution Approach 1:
The patent divides a single nozzle into multiple nozzles (e.g., 7 nozzles arranged in a circular pattern) within one extruder. Each nozzle can deposit material simultaneously, achieving both high resolution (through small nozzle diameters) and high productivity (through parallel material deposition). The segmented nozzle array allows the system to maintain fine feature capability while dramatically increasing printing speed.
Solution Approach 2:
The patent combines multiple nozzles into a single integrated extruder assembly that rotates as one unit. This merging of multiple nozzle functions into a single rotating component enables coordinated multi-point deposition while maintaining system simplicity. The combined extruder structure allows all nozzles to work together simultaneously, achieving both precision and speed.
2Productivity
If printing speed is increased by enlarging nozzle diameter, increasing printing speed, or increasing material flow rate, then productivity is improved, but manufacturing precision deteriorates due to compromised print resolution and surface defects
Solution Approach 1:
Instead of using one large nozzle that would cause surface defects, the system segments the material deposition across multiple small nozzles. Each small nozzle maintains high resolution capability while the collective output of all nozzles achieves high productivity. The segmentation allows parallel deposition without compromising surface quality.
Solution Approach 2:
The patent introduces rotational motion to the extruder assembly, making the nozzle array dynamic rather than static. The rotating extruder enables the nozzles to access different positions on the print bed continuously, increasing printing speed without requiring larger nozzle diameters. This dynamic approach maintains precision while achieving high productivity.
3Manufacturing precision
If a single fixed nozzle is used, then manufacturing precision is maintained, but adaptability deteriorates due to difficulty in printing with multiple materials simultaneously for functionally graded properties
Solution Approach 1:
The patent divides the single nozzle function into multiple independent nozzles, each capable of receiving different material sources. This segmentation enables multi-material printing while maintaining overall print quality, as each nozzle can be optimized for its specific material type while the rotating assembly ensures coordinated deposition.
Solution Approach 2:
The rotating extruder assembly serves multiple functions: it can print with a single material, multiple materials simultaneously, or switch between different material configurations. The universal design allows the same hardware to adapt to various printing requirements including functionally graded materials, while maintaining precision through consistent rotational control.
4Ease of manufacture
If traditional extrusion-based 3D printing is used with straight nozzles, then ease of manufacture is maintained, but adaptability deteriorates due to inability to print on internal surfaces of structures
Solution Approach 1:
The patent transforms the static straight nozzle into a dynamic rotating extruder assembly. The rotation enables the nozzles to reach internal surfaces of structures by approaching from different angles during the printing process. This dynamic motion maintains manufacturing simplicity while achieving the adaptability to print on complex geometries including internal surfaces.
Solution Approach 2:
The patent adds rotational motion as a new dimension to the traditional linear extrusion process. This dimensional change allows the nozzles to access internal surfaces that would be unreachable with fixed straight nozzles, while the rotational mechanism itself remains mechanically simple and easy to manufacture.
Data Source
AI summary
An extruder includes a housing, and a rotator coupled to the housing. The housing includes a first base, a plurality of holes in the first base, and a plurality of nozzle holders on the first base. The rotator rotates the housing during a 3D printing process. According to an implementation, a plurality of nozzles are accommodated in the plurality of nozzle holders. One or more of the plurality of nozzles are bent or curved.