Multi-Diameter Wire Feeding With Grooved Rollers for Metal 3D Printing
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Solution Overview
Problem
Current 3D printing methods using metal powders are costly, hazardous to handle, and inefficient due to high material waste and slow processing times.
Innovation Solution
A system and method for 3D printing using a wire feedstock, where the wire is directed from a source to a print head through rollers with grooves, reducing stress on the wire and enabling efficient deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal powder is used as feedstock for 3D printing, then the printing process can be performed, but the material cost increases and handling becomes hazardous
Solution Approach 1:
The patent changes the physical form of the feedstock from metal powder to metal wire, fundamentally altering the material parameters. This transformation eliminates the hazards associated with powder handling (dust inhalation, explosion risks) while maintaining the capability to perform 3D printing through wire-fed additive manufacturing processes
2Ease of manufacture
If metal powder is used as feedstock for 3D printing, then the printing process can be performed, but material waste increases due to attrition and inability to reuse
Solution Approach 1:
By changing the feedstock form from powder to wire, the patent enables precise material delivery and reduces material waste. Wire feedstock can be fed continuously and precisely controlled, minimizing attrition and allowing for better material utilization and potential reuse compared to powder-based systems
3Ease of manufacture
If conventional powder-based processes are used for 3D printing, then layers can be built, but processing time increases due to slow powder spreading
Solution Approach 1:
The patent changes the feedstock delivery mechanism from powder spreading to wire feeding. Wire-fed systems can continuously deposit material at higher rates without the time-consuming powder spreading and leveling operations required in powder-based processes, significantly improving processing speed and productivity
4Loss of substance
If wire is directed from source to print head, then material waste is reduced, but stress is imposed on the wire during direction
Solution Approach 1:
The patent introduces guide rollers as intermediary components between the wire source and print head. These rollers gently redirect the wire through curved paths, reducing stress concentrations that would occur with sharp bends or rigid routing, thereby preventing wire deformation while maintaining efficient material delivery
5Stress or pressure
If driver rollers with grooves are used to direct wire, then wire stress is reduced, but device complexity increases
Solution Approach 1:
The patent modifies the geometry of the driver rollers by adding grooves with specific curvature radii that match the wire diameter. This geometric parameter change allows the rollers to cradle and guide the wire smoothly, distributing stress along the contact surface rather than concentrating it at sharp edges, thereby reducing wire stress while maintaining relatively simple roller structures
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 reduces material waste, decreases processing time, and minimizes the hazards associated with handling metal powders, while maintaining the accuracy and complexity of 3D printed objects.
Implementation Method 1
a driver roller, which the driver roller comprising a groove that is configured to (i) accept at least a portion of the wire and (ii) direct the at least the portion of the wire towards the guide
Implementation Method 2
a power source in electrical communication with the wire and the support, wherein the power source is configured to supply electrical current from the guide through the wire and to the support, or vice versa, during printing of the 3D object
Implementation Method 3
the controller is configured to direct the power source to supply the electrical current from the guide through the wire and to the support, or vice versa, during printing of the 3D object under conditions sufficient to melt the wire when the wire is in contact with the support or the at least the portion of the 3D object
Data Source
AI summary
The present disclosure provides a system for printing a three-dimensional object. The system may comprise a support for holding a portion of the object and a wire(s) source configured to hold a wire(s) of substantially the same or different diameters. The system may also comprise a print head. The print head may comprise a guide for directing the wire to the support. The system may also comprise a driver roller comprising a groove configured to contact a portion of the wire and direct the wire to the guide, and a power source in electrical communication with the wire and the support. The system may also comprise a controller configured to direct the power source to supply electrical current to the wire and the support. The electrical current may be sufficient to melt the wire when the wire is in contact with the support or the portion of the object.