Ultrasonic Hammer Fused Deposition Modeling Density

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Solution Overview

Problem

Fused deposition modeling (FDM) processes face issues with material density due to bubble and cavity formation, resulting in lower density in the vertical direction, which affects the quality of deposited materials.

Innovation Solution

A fusion deposition system incorporating an ultrasonic hammer that compresses deposited thermoplastic materials at a predetermined temperature, improving density by applying compressive loads and eliminating cavities, utilizing an ultrasonic transducer and horn to enhance material properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional FDM deposition is used, then the deposition process is simple, but material density is low due to bubble and cavity formation

Engineering Contradiction:

Improvematerial densityVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the deposition nozzle and ultrasonic hammer into a single integrated tool head. The ultrasonic hammer is positioned adjacent to the nozzle and operates simultaneously with the deposition process, eliminating the need for separate post-processing equipment while achieving cavity elimination and density improvement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ultrasonic hammer applies high-frequency mechanical vibrations to the deposited material through a horn that contacts the material surface. This vibration energy breaks up bubbles and cavities within the material, consolidates layers, and increases density without requiring complex chemical or thermal processing.

Inventive Principle:

Principle #18Mechanical vibration

2Manufacturing precision

If ultrasonic hammering is applied, then material density increases, but energy consumption increases

Engineering Contradiction:

Improvematerial densityVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The ultrasonic hammer operates in periodic pulses rather than continuous operation. The system applies ultrasonic energy in controlled intervals during the deposition process, allowing the material to cool slightly between pulses and reducing overall energy consumption while maintaining effective cavity elimination.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system dynamically adjusts ultrasonic parameters including frequency, amplitude, and duty cycle based on material properties and deposition conditions. This optimization ensures minimum effective energy input is used to achieve the required density improvement without excessive energy consumption.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If ultrasonic hammering is applied, then cavity elimination improves, but processing time increases

Engineering Contradiction:

Improvecavity eliminationVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The ultrasonic hammering action is applied immediately after material deposition while the material is still in a semi-plastic state. This preliminary action prevents cavity formation rather than requiring subsequent remediation, integrating the density improvement process into the deposition itself rather than adding separate processing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The ultrasonic hammering operates continuously alongside the deposition process rather than as a separate post-processing step. The tool head moves synchronously with the nozzle, applying vibration energy continuously to each deposited layer as it is laid down, maintaining productivity while achieving thorough cavity elimination.

Inventive Principle:

Principle #20Continuity of useful action

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

The system effectively increases material density and improves the quality of deposited objects by removing cavities and enhancing structural strength, ensuring consistent and high-quality prints.

Implementation Method 1

hammering the deposited material with the ultrasonic hammer to compress the deposited material, wherein the deposited material is at a second predetermined temperature

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

compress the deposited material

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS10137631B2Device, system, and method for fused deposition modeling

Publication Date: 2018.11.27 TOYOTA JIDOSHA KK

AI summary

A system and method for fused deposition modelling that deposits using a nozzle a material on a substrate at a first predetermined temperature, moves, using processing circuitry, the nozzle and an ultrasonic hammer at a predetermined speed in a predetermined pattern to create an object, and hammers the deposited material using the ultrasonic hammer to compress the deposited material, wherein the deposited material is at a second predetermined temperature.