Thin-Wire Extrusion for 3D Printed Bare Lead Structures
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Solution Overview
Problem
Existing 3D printing technologies struggle to extrude thin wires without relying on the curing, drying, or solidifying of the printing medium, making it impossible to extrude bare wire sections or place wires between layers of the medium.
Innovation Solution
A two-part system consisting of a wire extruder and a wire injector, which grip, push, and extrude thin wires into a 3D printing medium or structure without relying on the curing or solidifying of the medium, allowing for the extrusion of bare wire sections and placement between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional wire feeding mechanisms rely on curing, drying, or solidifying of the printing medium to extrude wire, then the wire can be extruded within the printing medium layer, but bare wire sections cannot be extruded and wire placement between layers is restricted
Solution Approach 1:
The system is divided into two independent parts: a wire extruder mechanism and a printing medium extruder mechanism. The wire extruder uses a motor-driven capstan with tensioning to feed wire independently, while the printing medium extruder uses a piston or screw mechanism. This segmentation allows wire to be extruded without relying on the printing medium's curing, drying, or solidifying, enabling bare wire sections and placement between layers.
Solution Approach 2:
The wire feeding system uses a motor-driven capstan with adjustable speed and a spring-loaded tensioning mechanism that dynamically adjusts to maintain constant wire tension during extrusion. This dynamic control allows the wire to be pushed through the dispensing tip without relying on the printing medium's phase changes, enabling versatile wire placement options including bare sections and inter-layer positioning.
2Adaptability or versatility
If traditional mechanisms extrude wire with simultaneous extrusion of printing medium, then the wire is placed within the medium layer, but bare wire sections and inter-layer placement become impossible
Solution Approach 1:
The system separates wire extrusion from printing medium extrusion into independent mechanisms. The wire extruder uses a motor-driven capstan with tensioning to control wire feed rate independently, while the printing medium extruder operates separately. This allows three extrusion modes: wire only (for bare leads), wire with medium (for embedded wires), and medium only, providing versatility without compromising precision through independent control of each mechanism.
Solution Approach 2:
A dispensing tip serves as an intermediary component where wire and printing medium are combined or separated. The tip geometry and positioning control whether wire emerges with medium (embedded) or separately (bare leads). This intermediary structure enables flexible extrusion modes while maintaining precise wire placement through controlled interaction at the dispensing point.
3Adaptability or versatility
If thin wires (30-40 AWG) are extruded without curing, drying, or solidifying mechanisms, then bare wire sections can be created, but the wire may buckle or deform during extrusion
Solution Approach 1:
The wire extruder employs a motor-driven capstan with a spring-loaded tensioning mechanism that dynamically maintains constant tension on the wire during extrusion. The tensioning spring compensates for variations in wire feed rate and resistance, preventing buckling of thin wires (30-40 AWG). This dynamic tension control enables bare wire lead capability while maintaining wire structural integrity throughout the extrusion process.
Solution Approach 2:
The tensioning mechanism provides continuous feedback on wire tension during extrusion. The spring-loaded idler bearing adjusts tension based on resistance encountered, ensuring the wire remains taut and prevents buckling. This feedback mechanism allows bare wire sections to be extruded reliably while maintaining structural integrity of thin wires throughout the process.
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 effective extrusion of thin wires (30-40 AWG) with or without simultaneous extrusion of a printing medium, allowing for the creation of structures with bare wire leads and improved wire placement within 3D printed structures.
Implementation Method 1
a tensioner spring in compression between the housing and the tensioner arm
Implementation Method 2
the drive wheel centers and grips the wire under tension provided by the idler bearing pressing against the wheel and wire
Implementation Method 3
guides the wire into a low-friction tube to constrain the wire to the dispensing tip/nozzle
Data Source
AI summary
An apparatus for the extrusion of a solid wire into a resin or paste is disclosed. The apparatus consists of two main parts including an adapter for constraining the wire until mixing with the resin or paste (‘wire injector’), and a motor-driven gear system that feeds the wire into the injector (‘wire extruder’). With this system, a bare wire can be extruded allowing for the creation of lead-in/lead-out sections, or for use with a resin or paste without an inherent curing, drying, or solidifying mechanism. Additionally, this apparatus allows for the extrusion of small (30-40 AWG) wires, enabling unique applications such as the injection of a resistive wire where smaller diameter wires are advantageous for minimized electrical or thermal overhead.