Sheet-Shaped 3D Printing Filament for Diameter Tolerance Control
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Solution Overview
Problem
The high cost and variability of filament diameter in FDM printing, along with challenges in drying and shape tolerance, lead to undesirable visual defects and inefficiencies in 3D printed objects.
Innovation Solution
A method involving the shaping of elongated strips into 3D printable filaments through twisting, rolling, bending, or folding to create a 3D printable material with improved thickness accuracy, which is then fed into a 3D printer for layer-wise deposition, using thermoplastic polymers with optional additives for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filament with constant diameter is produced for FDM printing, then printing quality and shape accuracy are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent changes the fundamental parameter of filament geometry from circular to rectangular cross-section. This parameter change allows the use of standard extrusion processes with conventional materials (like PVC) while achieving consistent dimensions, thereby maintaining manufacturing precision without significantly increasing production cost
Solution Approach 2:
The patent employs inexpensive materials such as PVC for filament production, replacing expensive specialized filaments. The rectangular cross-section design enables cost-effective manufacturing while still providing sufficient precision for 3D printing applications
2Ease of manufacture
If filament diameter varies, then manufacturing cost decreases, but printing quality and shape accuracy deteriorate
Solution Approach 1:
The patent changes the cross-sectional geometry parameter from circular to rectangular, which fundamentally alters how dimensional variations affect printing quality. The rectangular shape with defined width and height provides better tolerance control at lower cost, as standard extrusion processes can more easily maintain consistent rectangular dimensions compared to circular ones
3Productivity
If thicker filament is used, then material flow rate increases, but drying time and processing complexity increase
Solution Approach 1:
The patent changes the cross-sectional geometry to rectangular, which optimizes the surface area to volume ratio for drying purposes. The rectangular shape with specific width-height proportions allows faster moisture evacuation while maintaining adequate material flow rate for productive printing
4Ease of manufacture
If rectangular cross-section filament is used instead of circular, then manufacturing cost decreases and drying time reduces, but conventional extrusion processes must be adapted
Solution Approach 1:
The patent changes the cross-sectional geometry parameter to rectangular, which actually simplifies the extrusion process by allowing the use of standard flat-die extrusion equipment rather than requiring specialized circular die setups. This parameter change reduces device complexity while lowering costs
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 reduces drying time and manufacturing costs while improving shape accuracy and enabling complex layer structures with varied properties, resulting in cost-effective and efficient 3D printing.
Implementation Method 1
melting the 3D printable filament in the printer head of the 3D printer
Implementation Method 2
an outer liquefier portion configured to receive thermal energy from the heat transfer component
Implementation Method 3
the ribbon liquefier is configured to melt the ribbon filament received in the channel to at least an extrudable state with the received thermal energy
Data Source
Figure 1
Figure 1A~2
Figure 3
AI summary
The present invention relates to a method for manufacturing a 3D item by means of fused deposition modelling, the method comprising the steps of: a) providing a 3D printable material in the form of at least one elongated strip (1) having a first longitudinal extension (L1), a first transverse extension (W1) being substantially perpendicular to the first longitudinal extension (L1) and a first height (T1) being substantially perpendicular to the first longitudinal extension (L1) and the first transverse extension (W1), the 3D printable material comprising at least one thermoplastic polymer; b) shaping, by means of at least one of twisting and rolling around an axis parallel to the first longitudinal extension (L1), the at least one elongated strip (1) into a 3D printable filament (2) having a second longitudinal extension (L2), a second transverse extension (W2) being substantially perpendicular to the second longitudinal extension (L2) and a second height (T2) being substantially perpendicular to the second longitudinal extension (L2) and the second transverse extension (W2); c) feeding the 3D printable filament (2) to a printer head (500) of a 3D printer (400); d) melting the 3D printable filament in the printer head (500) of the 3D printer (400); and e) layer-wise depositing the 3D printable material to provide the 3D item comprising a plurality of layers of 3D printed material.