Sheet-Formed 3D Printing Filament for Consistent Diameter
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Solution Overview
Problem
Current FDM 3D printing technologies face high costs due to expensive filaments with inconsistent diameters, leading to visual defects and difficulties in drying processes.
Innovation Solution
Manufacture 3D printable filaments by shaping elongated strips of thermoplastic polymer into filaments through twisting, rolling, or bending, resulting in high thickness accuracy and reduced drying times, using sheets cut into thin strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filaments with constant diameter are used, then printing speed and consistency are improved, but production cost increases significantly
Solution Approach 1:
The invention divides the filament manufacturing process into two independent stages: first producing flexible strips from sheet material, then forming filaments by twisting and rolling these strips. This segmentation allows each stage to be optimized independently, using cost-effective sheet production methods while achieving the required filament consistency through controlled mechanical forming processes.
Solution Approach 2:
The invention changes the physical state and form of the material from rigid filament to flexible strip, then back to filament through controlled deformation. By manipulating the mechanical properties of the material during the twisting and rolling process, the invention achieves consistent filament diameter without requiring expensive precision manufacturing of the final filament form.
2Manufacturing precision
If conventional filaments with constant diameter are used, then printing consistency is improved, but drying process becomes more difficult
Solution Approach 1:
Instead of drying complete filaments before printing, the invention inverts the sequence by drying the flexible strips before they are formed into filaments. This inversion allows the thin strip material to dry quickly due to its high surface area to volume ratio, while the final filament formation occurs after drying, avoiding the time-consuming drying of thick filaments.
3Ease of manufacture
If sheet material is shaped into filaments through twisting and rolling, then production cost and drying time are improved, but manufacturing complexity increases
Solution Approach 1:
The invention employs self-service mechanisms where the flexible strip material naturally conforms to the shaping tools during twisting and rolling operations. The material's inherent flexibility allows it to be formed into filaments through relatively simple mechanical actions rather than complex controlled processes, reducing the need for sophisticated equipment while maintaining filament consistency.
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 method reduces production costs and improves manufacturing efficiency by using high-speed, cost-effective sheet material production, enhancing the accuracy and quality of 3D printed objects.
Implementation Method 1
melting the 3D printable filament in the printer head of the 3D printer
Data Source
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.