Sealing Needle Nozzle for Precision Pharma 3D Printing
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Solution Overview
Problem
Current additive manufacturing technology faces challenges in precision, particularly in extruding materials for pharmaceutical products, where uniform shape and precise drug dosage are critical.
Innovation Solution
A device with a material supply system that melts and pressurizes materials, featuring a nozzle with a tapered inner surface and a control switch with a sealing needle that engages the nozzle to inhibit material flow, allowing for precise control of material deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is melted and pressurized for extrusion, then material flow is enabled, but unintended leakage occurs from the printing nozzle
Solution Approach 1:
A sealing needle is introduced as an intermediary component between the material supply system and the printing nozzle. The sealing needle can be positioned to seal the feed channel and control the flow of melted material, preventing unintended leakage while allowing controlled extrusion through the printing nozzle.
Solution Approach 2:
The sealing needle is made movable between different positions (sealed and open) to dynamically control material flow. This dynamic adjustment allows the system to switch between preventing leakage and enabling extrusion as needed, resolving the contradiction between productivity and leakage control.
2Ease of manufacture
If conventional additive manufacturing is used, then manufacturing capability is achieved, but precision and uniformity are insufficient for pharmaceutical products
Solution Approach 1:
A pressure sensor is integrated into the system to provide real-time feedback on material pressure within the printing nozzle. This feedback allows the control system to adjust the pressing force and material flow rate dynamically, ensuring consistent extrusion precision and uniformity required for pharmaceutical manufacturing.
Solution Approach 2:
The system dynamically adjusts critical parameters including pressing force, material temperature, and extrusion rate based on real-time pressure feedback. These parameter changes enable precise control over material deposition, achieving the manufacturing precision required for pharmaceutical dosage forms.
3Object-generated harmful factors
If sealing needle is added to control material flow, then leakage is reduced, but device complexity increases
Solution Approach 1:
The sealing function is extracted as a separate, dedicated component (sealing needle) that can be independently controlled. This modular approach allows the sealing mechanism to be added without fundamentally redesigning the entire system, managing complexity by isolating the leakage control function.
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
The device achieves precise and accurate deposition of materials, reducing unintended leakage and ensuring uniformity and precision in manufacturing pharmaceutical dosage forms.
Implementation Method 1
a material supply system configured to melt and pressurize the material
Implementation Method 2
a pressure sensor configured to detect pressure of the material within the nozzle or the feed channel proximal to the nozzle
Implementation Method 3
the tapered end of the sealing needle engages the tapered inner surface of the nozzle to inhibit material flow through the nozzle when the sealing needle is in the closed position
Data Source
AI summary
Provided herein are devices and systems for depositing a material or manufacturing a product, such as a pharmaceutical dosage form, by additive manufacturing. Further provided are methods of using the devices and systems, as well as methods of manufacturing a product, such as a pharmaceutical dosage form, by additive manufacturing. In certain embodiments, the device includes a material supply system configured to melt a pressurized a material, a pressure sensor configured to detect a pressure of the material within the device, and a control switch comprising a sealing needle operable in an open position and closed position. The sealing needle extends through a feed channel containing the material and includes a taper end, wherein the tapered end of the sealing needle engages a tapered inner surface of a nozzle to inhibit flow of the material through the nozzle when the sealing needle is in the closed position.