Straight Axis Nozzle Hopper Alignment for Rigid Filament 3D Printing
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Solution Overview
Problem
Existing FFF machines are limited by the flexibility of build materials, which restricts the choice of materials and results in three-dimensional objects with poor mechanical properties compared to injection molding.
Innovation Solution
The nozzle opening and hopper opening are aligned on a straight axis, allowing build materials with higher viscosity and non-flexible materials to be used, with reduced residence time in a flowable state, enabling the use of materials like glass fiber-filled thermoplastics and thermally conductive fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible build material is used to allow winding around a bobbin and easy transport, then ease of operation and material transport are improved, but the choice of materials is limited and mechanical properties deteriorate
Solution Approach 1:
The build material is segmented into discrete elements ( pellets, flakes, or short fibers) rather than requiring continuous flexible filament. These segmented materials are fed individually through the hopper opening into the heating zone, eliminating the need for flexibility while enabling diverse material selection including rigid and thermally conductive materials.
Solution Approach 2:
A hopper opening aligned with the nozzle opening on a straight axis serves as an intermediary structure that receives segmented build material and directs it into the heating zone. This intermediary allows rigid materials to be transported and processed without requiring flexibility, while maintaining efficient material flow to the nozzle.
2Strength
If build material residence time in flowable state is reduced, then material viscosity and mechanical properties are improved, but processing efficiency may worsen
Solution Approach 1:
The hopper opening is positioned to deliver build material directly into the heating zone where it is rapidly heated to flowable state and immediately directed to the nozzle. This preliminary positioning and rapid processing minimize residence time in the flowable state, preventing excessive heating that would degrade mechanical properties while maintaining processing efficiency through continuous material flow.
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 enhances the mechanical performance of three-dimensional objects by allowing the use of rigid and thermally conductive materials, improving Young's modulus and maintaining filler orientation, resulting in objects with improved mechanical properties.
Implementation Method 1
a heating element connected to the movable nozzle... heating the build material to a flowable state
Implementation Method 2
Upon leaving the movable nozzle, the build material cools in the surrounding air and transitions back to the non-flowable state
Data Source
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AI summary
Apparatus and methods for producing three-dimensional objects are disclosed. The apparatus for solid freeform fabrication comprises a movable nozzle (1) comprising a nozzle opening (2), a heating element (3) connected to the movable nozzle, a driver (4) connected to the movable nozzle, a platform (5) for receiving a build material (8) from the movable nozzle, and a hopper (6) for providing the build material to the driver, the hopper comprising a hopper opening (7), wherein the nozzle opening and the hopper opening are capable of simultaneous alignment on a straight axis such that the build material, when present, is capable of traveling along the straight axis at least from the hopper opening until the build material attains a flowable state.