Single Nozzle 3D Printer Extruder with Mixer and Heat Sink
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Solution Overview
Problem
Current three-dimensional printing technologies face challenges with dual-nozzle systems, which are complex to calibrate, prone to material contamination and mixing, and risk damage to printed layers due to nozzle movement, especially when printing with multiple materials like soluble and insoluble thermoplastics.
Innovation Solution
A single-nozzle extruder assembly with a mixer and heat sink, featuring angled feeding means to minimize filament deformation and contamination, and a heat sink to isolate the heating block from other components, reducing thermal exposure and clogging, while using fluorinated polymers for smooth filament handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dual-nozzle system is used for printing with multiple materials, then printing capability with multiple materials is improved, but device complexity and calibration difficulty increase
Solution Approach 1:
The patent combines multiple material feeding capabilities into a single nozzle system. The mixer receives multiple filaments and merges them into one stream that passes through a single heating block and nozzle, eliminating the need for multiple nozzles while maintaining multi-material printing capability
Solution Approach 2:
The single nozzle system is designed to handle multiple materials universally. The mixer and single heating block can process different filament types (soluble and insoluble materials) through one unified extrusion path, making the system versatile for various material combinations
2Adaptability or versatility
If dual-nozzle system is used, then multi-material printing is enabled, but risk of material contamination and mixing increases
Solution Approach 1:
The patent extracts the mixing function from the nozzle itself and places it in a dedicated mixer component upstream. This separation allows controlled mixing of materials before they enter the heating block, preventing unwanted contamination while enabling intentional blending where required
Solution Approach 2:
The mixer acts as an intermediary component between the multiple filament sources and the single heating block. It mediates the interaction between different materials, controlling their mixing and preventing direct contamination in the nozzle while maintaining material integrity
3Adaptability or versatility
If dual-nozzle system is used, then multi-material printing is achieved, but risk of damage to printed layers by nozzle movement increases
Solution Approach 1:
By merging multiple material streams into a single nozzle, the system eliminates the need for multiple nozzles that could collide or interfere with each other. The single nozzle moves uniformly without risk of one nozzle damaging layers deposited by another nozzle
4Productivity
If filaments are fed at high angle to nozzle axis, then feeding efficiency is improved, but filament deformation increases
Solution Approach 1:
The patent optimizes the feeding angle parameter to a specific range (10-60 degrees relative to the longitudinal axis of the nozzle) that balances feeding efficiency with filament integrity. This parameter optimization ensures smooth filament flow while preventing deformation
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 solution allows for reliable printing with multiple materials without complex calibration, reduces material consumption and clogging, and prevents contamination, enhancing printing precision and efficiency by maintaining minimal melted material in the nozzle and shortening filament change times.
Implementation Method 1
a heat sink, arranged between the heating block and the mixer
Implementation Method 2
a heating block, a temperature control element for controlling the temperature of the heating block
Implementation Method 3
a temperature control element for controlling the temperature of the heating block
Data Source
Figure 1
Figure 2
AI summary
The present invention provides an extruder assembly for a three-dimensional printer comprising one nozzle (1), attached to a heating block (2), a temperature control element for controlling the temperature of the heating block, a mixer (5), a heat exchanger (4) arranged between the heating block (2) and the mixer (5), and a plurality of feeding means for feeding a plurality of printing material filaments from filament storage means to the mixer (5) and from retracting the printing material filaments from the mixer (5), arranged to feed the filaments into the mixer (5). The extruder assembly is suitable for 3D printing using a plurality of printing materials.