Variable Cross-Section Nozzle for 3D Printing Speed and Detail Trade-off

Solution Overview

Problem

Current three-dimensional printing methods using fused deposition are limited by the inability to change nozzles during printing, requiring a compromise between print quality and speed, which results in suboptimal printing outcomes.

Innovation Solution

A three-dimensional printing method utilizing a nozzle with a variable cross-section, allowing the cross-section to change during printing from a maximum to a minimum cross-section, enabling precise outline deposition and detailed features while maintaining high filling speed for solid portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a nozzle with a small cross-section is chosen, then the printing of details arranged close to free edges of the part is improved, but the filling of the portions of the part which are not arranged close to free edges of the part is performed very slowly

Engineering Contradiction:

Improvedetail qualityVSAvoidfilling speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The nozzle cross-section is made variable rather than fixed, allowing it to dynamically adapt its size during the printing process. The system switches between a first cross-section for filling operations and a second cross-section for detail printing, resolving the contradiction by making the nozzle configuration dynamic rather than static.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The physical parameter of the nozzle (cross-sectional area) is changed between two distinct values depending on the operational requirement. The system uses a first cross-section value during filling operations and switches to a second cross-section value during detail printing, allowing optimization of both speed and precision.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If a nozzle with a large cross-section is chosen, then the filling of portions of the part is performed rapidly, but the details arranged close to the free edges of the part cannot be printed with satisfactory quality

Engineering Contradiction:

Improvefilling speedVSAvoiddetail quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The nozzle cross-section is made variable rather than fixed, allowing it to dynamically adapt its size during the printing process. The system switches between a first cross-section for filling operations and a second cross-section for detail printing, resolving the contradiction by making the nozzle configuration dynamic rather than static.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The physical parameter of the nozzle (cross-sectional area) is changed between two distinct values depending on the operational requirement. The system uses a first cross-section value during filling operations and switches to a second cross-section value during detail printing, allowing optimization of both speed and precision.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If a fixed nozzle cross-section is used, then the device complexity is reduced, but the printing process requires a compromise between fineness and speed resulting in suboptimal outcomes

Engineering Contradiction:

Improvenozzle configurationVSAvoidoverall printing efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The nozzle system is designed to perform multiple functions using a single configurable component. The same nozzle can operate with different cross-sections depending on the task, eliminating the need for multiple separate nozzles or nozzle changes while achieving both fast filling and precise detail printing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The nozzle cross-section is made variable rather than fixed, allowing it to dynamically adapt its size during the printing process. The system switches between a first cross-section for filling operations and a second cross-section for detail printing, resolving the contradiction by making the nozzle configuration dynamic rather than static.

Inventive Principle:

Principle #15Dynamics

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 optimizes production time by reserving the minimum cross-section for detailed features and the maximum cross-section for filling, achieving a balance between print quality and speed that is not possible with fixed nozzle sizes.

Implementation Method 1

passing a thermoplastic filament through a print head comprising a heating element and a calibrated nozzle. A spool of thermoplastic filament supplies the heating element which liquefies this filament

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the heating element which liquefies this filament

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250121562A1Process for three-dimensional printing with variable cross-section

Publication Date: 2025.04.17 SAFRAN HELICOPTER ENGINES

AI summary

A process for three-dimensional printing of a workpiece including a succession of steps for producing a layer of the workpiece by means of a nozzle which has an output cross-section along a path of the nozzle, wherein, during at least one step for producing a layer, use is made of at least one nozzle, an output portion of which has an output cross-section which is variable between a first maximum cross-section and a second minimum cross-section, and wherein the cross-section of at least one part of an output portion of the nozzle is varied along at least one portion of the path.