Material Extrusion with Selective Infill Control
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Solution Overview
Problem
Existing material extrusion methods in additive manufacturing require multiple filaments or frequent filament changes to achieve different material compositions in various areas of a component, limiting control over localized material properties and structural integrity.
Innovation Solution
A method involving a hopper of primary material and an infill material, where the infill material is selectively integrated into the primary material within an extruder, allowing for controlled deposition through a nozzle to form components with varying properties, including the use of chopped fibers, continuous fibers, or beads, to enhance strength and thermal expansion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple distinct filaments are fed to distinct nozzles to achieve different material compositions, then material composition variety is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple material delivery capabilities into a single nozzle system by integrating a hopper that can receive both primary filament material and infill material, allowing one nozzle to extrude composite materials with varying compositions without requiring multiple nozzles or filament changing mechanisms
Solution Approach 2:
The hopper acts as an intermediary component that receives and manages both primary filament and infill material separately, then delivers them through a single nozzle in controlled proportions, enabling material composition variety without the complexity of multiple nozzles
2Adaptability or versatility
If filament is stopped and changed to achieve different material compositions, then material composition variety is improved, but productivity decreases
Solution Approach 1:
The system maintains continuous extrusion operation by having both primary filament and infill material available in the hopper simultaneously, allowing the nozzle to extrude different material compositions without stopping or changing filaments, thus maintaining continuous productive action throughout the printing process
3Strength
If infill material is selectively added to enhance strength at certain areas, then localized strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements local quality by selectively adding infill material to specific regions of the component based on structural requirements, allowing different areas to have different material compositions and properties, with the controller determining exactly where infill should be incorporated into the extruded filament
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
Enables the creation of components with tailored mechanical and thermal properties, improved strength, and customized areas within a single monolithic structure, addressing the limitations of prior art by allowing for precise control over material composition and structural integrity.
Implementation Method 1
a filament is typically provided to a manufacturer, and is fed to a nozzle, where it is melted and then deposited
Implementation Method 2
material extrusion wherein an infill secondary material is added into a primary material
Data Source
AI summary
A method of forming a component utilizing material extrusion includes the steps of (1) delivering a hopper of particulate media formed of a primary material into an extruder, (2) selectively providing an infill material into the primary material within the extruder, (3) delivering a filament of the primary material and the infill material downstream to a nozzle where it is then deposited to form the component, and (4) a control associated with the nozzle selectively delivering the infill material into the primary material, or blocking a delivery of the infill material into the primary material dependent on an area in the component which is being formed.