AUTOMATED MULTI-FILAMENT FEEDING AND SWITCHING MECHANISM FOR ADDITIVE MANUFACTURING

Abstract

The invention relates to a multi-filament feeding mechanism designed for additive manufacturing processes, specifically addressing the challenges of multi-material part fabrication. The system incorporates a rotating disc equipped with multiple slots, each slot holding a different type of filament. This rotating disc, in conjunction with a vertically movable nozzle controlled by a gear mechanism, allows for automated and precise switching between filaments during the printing process. The mechanism includes a stepper motor-driven roller system that feeds filament into the nozzle, where it is heated and liquefied for extrusion. The disc rotates to align the desired filament with the nozzle, enabling quick and efficient switching between materials without manual intervention. This system enhances operational flexibility, reduces machine downtime, and improves efficiency, particularly in multi-material 3D printing applications. The vertical movement of the nozzle, coupled with precise filament alignment, ensures consistency in filament feeding and extrusion, contributing to more accurate and high-quality printing results. The invention’s versatility makes it a valuable solution for advancing multi-material manufacturing.

Specification

Description:The following specification particularly describes the invention and the manner in which it is to be performed.
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application does not claim priority from any patent application.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to additive manufacturing particularly 3D printing.
BACKGROUND
[003] In the evolving field of additive manufacturing, particularly 3D printing, the demand for multi-material fabrication has grown significantly. Traditional 3D printers are often limited to using one or two materials simultaneously, which constrains their application in producing complex, multi-material parts. This limitation leads to frequent manual filament changes and increased downtime, reducing overall production efficiency. To address this, there has been a need for systems that can seamlessly manage multiple types of filament materials without compromising the speed and precision of the printing process. Current multi-material systems are either expensive, overly complex, or require extensive user intervention, making them less viable for dynamic manufacturing environments.
[004] US8827684B1, A fused filament fabrication printer has a fixed extrusion module having multiple printheads having print tips. The fixed arrangement of the printing heads allows the close spacing of multiple print tips in a printhead unit, and the simple routing of multiple plastic or metal filaments to the individual printing heads. The closely spaced print tips in the printhead unit share common components. An exemplary printhead unit has four printing heads which share a common heating block and heating block temperature sensor. The heating block incorporates a group of four print tips evenly spaced along a line. Each printing head has a separate filament which is controlled and driven by its own stepper motor through the heating block to one of the print tips. Printing of a part is by control of individual stepper motors which drive filaments through the heating block and through one of the printing tips. However the invention incorporates multiple printing tips due to which maintenance issues may arise.
[005] JP6977080B2, The present disclosure relates to a print head and an extruder used in a three-dimensional object printer, and more specifically to an extrusion print head that extrudes extruded material from two or more nozzles. However for efficient operation, Multiple nozzles are utilized in the invention
OBJECT
[006] The primary objective of this invention is to enable quick and automated filament switching in 3D printing processes, thereby improving the efficiency of multi-material manufacturing. Another key objective is to ensure precision in filament feeding, thus enhancing the quality and accuracy of material deposition during the printing process. This invention aims to reduce manual intervention and operational downtime while allowing manufacturers to switch between a variety of materials in a seamless and automated manner. By integrating a rotating disc with multiple slots for filament accommodation, the system seeks to enhance the operational flexibility of 3D printers, enabling the production of complex multi-material parts with minimal disruption.
SUMMARY
[007] This invention introduces a multi-filament feeding mechanism designed for additive manufacturing, particularly 3D printing applications that involve the use of multiple materials. The system comprises a rotating disc with multiple slots, each designated for different filament materials. The disc rotates to align a selected slot with a nozzle and heating arrangement, which moves vertically using a gear mechanism to facilitate precise filament feeding. The stepper motor-driven roller system ensures consistent material flow, while the automated rotation of the disc enables rapid switching between filaments without manual intervention.
[008] This system significantly improves operational efficiency, reduces downtime, and enhances the flexibility of multi-material fabrication processes by allowing quick filament changes. By addressing the challenges of multi-material handling, this invention offers a streamlined solution that advances the capabilities of 3D printing technology.
BRIEF DESCRIPTION OF DRAWINGS
[009] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present subject matter, an example of the construction of the present subject matter is provided as figures; however, the invention is not limited to the specific method disclosed in the document and the figures.
[0010] FIG 1: Illustrates the working of the model with the help of a chart
DETAILED DESCRIPTION
[0011] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any product used for additive manufacturing may be used in the practice or testing of embodiments of the present disclosure.
[0012] In this embodiment, the rotating disc plays a pivotal role in expanding the versatility of the multi-filament feeding mechanism by allowing for a customizable number of slots. Each slot is specifically designed to hold a different filament material, offering significant flexibility in material selection for additive manufacturing processes. The number of slots on the disc can be tailored to the specific needs of the user, providing more options for multi-material or multi-color 3D printing. For example, the disc can be configured to accommodate four slots for basic multi-material tasks, or expanded to include more slots to handle a larger variety of filaments. This customization enhances the system's ability to manage diverse material properties, such as different melting points, colors, or mechanical characteristics, all within a single printing process.
[0013] The rotating mechanism ensures that the selected filament is aligned precisely with the nozzle for extrusion, with each slot rotating into position as required. This design is particularly beneficial for industries that require frequent material changes or the use of complex material combinations, as it eliminates the need for manual intervention and reduces downtime typically associated with filament switching. The customizable disc increases the operational efficiency and adaptability of the system, making it a scalable solution that can be adjusted based on the complexity of the manufacturing task. By allowing the disc to hold more filaments, the system addresses the challenge of multi-material production, offering a streamlined and automated approach to filament management.
[0014] In another embodiment, the gear mechanism is integral to achieving the precise vertical movement of the nozzle, which is crucial for its proper alignment with the filament material fed from the rotating disc. The gear mechanism is driven by a stepper motor, which allows for controlled and accurate adjustments in the Z-axis. This movement ensures that the nozzle is perfectly positioned to receive the selected filament from the disc slot. The vertical movement of the nozzle is synchronized with the rotation of the disc, allowing the system to efficiently transition between different filaments without any manual adjustments.
[0015] The gear mechanism enables the nozzle to move up and down smoothly, ensuring that it makes contact with the disc at the correct height for each filament type. This precision in movement is vital for maintaining a consistent flow of material during the printing process, as it prevents misalignment that could lead to disruptions in extrusion or poor-quality prints. The ability to precisely control the nozzle's vertical position also allows the system to handle filaments of varying diameters or characteristics, further enhancing the flexibility and versatility of the multi-filament feeding mechanism. By ensuring precise alignment through the gear-driven vertical movement, the invention optimizes the filament feeding process, improving both the quality and efficiency of multi-material 3D printing operations.
[0016] In another embodiment, the nozzle's vertical movement is driven by a stepper motor, which plays a crucial role in ensuring precise control during the filament extrusion process. The stepper motor enables highly accurate, incremental movements along the Z-axis, allowing the nozzle to be positioned at the optimal height for each type of filament being used. This precision is essential in additive manufacturing, as it guarantees that the nozzle is correctly aligned with the selected filament material, ensuring smooth extrusion and preventing blockages or irregularities in the printing process.
[0017] The stepper motor's ability to provide controlled vertical movement allows for consistent material flow as the filament is heated and extruded through the nozzle. The fine control afforded by the stepper motor also supports the system's ability to handle a wide variety of filament types, each with unique properties such as thickness, melting point, and flow rate. This adaptability makes the invention suitable for multi-material 3D printing applications, where precise extrusion is vital for creating high-quality, intricate parts.
[0018] By coordinating the nozzle's vertical movement with the rotation of the filament disc, the system ensures that the nozzle and filament are perfectly aligned during each material change. This synchronization minimizes errors, reduces material waste, and enhances the overall efficiency of the 3D printing process. Additionally, the stepper motor-driven movement contributes to the system's ability to switch filaments rapidly and seamlessly, further optimizing the workflow in multi-material manufacturing tasks.
[0019] In another embodiment, the filament retraction system ensures that the currently engaged filament is retracted before switching to another filament material via the rotating disc. The system is designed to prevent filament overlap or clogging during the switching process, which is crucial for maintaining smooth operation in multi-material 3D printing. When a filament is no longer needed, the system activates the retraction mechanism, pulling the filament back from the heating zone and nozzle, which clears the pathway for the next filament to be engaged.
[0020] The retraction process is carefully controlled, often using a stepper motor or similar actuator to pull the filament back into its designated slot on the rotating disc. This precise movement ensures that the filament is fully retracted, avoiding residual material being left in the heating zone that could cause contamination or mixing of different materials. Once the filament is retracted, the disc rotates to align a new filament with the nozzle, after which the new filament is fed into the heating element for extrusion.
[0021] The filament retraction system is critical in preserving the integrity of each material, as it allows the printer to handle multiple types of filaments without cross-contamination or material degradation. Additionally, the automated nature of the retraction mechanism reduces the need for manual intervention, streamlining the process and minimizing the downtime between material changes. This system thus enhances the efficiency and flexibility of multi-material manufacturing, providing a smooth transition between different filaments while maintaining high-quality output.
[0023] In another embodiment, the heater arrangement is designed to adjust its temperature based on the specific filament material being fed into the nozzle, ensuring optimal extrusion conditions for each type of material. Different filaments, such as PLA, ABS, or PETG, require specific temperature ranges to melt properly and maintain their flow characteristics. The heater is equipped with a temperature control system, which can detect the type of filament through either pre-programmed settings or real-time sensing mechanisms.
[0024] When a filament is selected and aligned with the nozzle, the system automatically adjusts the heater's temperature to match the material's required melting point. For example, if the filament is PLA, which typically requires a lower extrusion temperature, the heater will reduce the temperature to around 180-220°C. Conversely, for filaments like ABS, which need higher temperatures (around 230-260°C), the heater adjusts accordingly. This flexibility ensures that the filament is heated to its optimal liquefaction point before extrusion, preventing issues like under-extrusion or clogging.
[0025] The heater arrangement also incorporates a feedback mechanism, using sensors to continuously monitor the temperature in real time. This allows the system to make fine adjustments if fluctuations occur, ensuring consistent filament flow and material deposition. The integration of such a system is particularly important in multi-material 3D printing, where different filaments with varying properties are frequently used in the same print job. By dynamically adjusting the temperature for each material, the heater arrangement enhances both the quality of the printed parts and the efficiency of the 3D printing process, minimizing material waste and printing errors.
[0026] In another embodiment, the rotating disc is designed to rotate by 90 degrees to align a different slot with the nozzle, enabling quick and efficient switching between various filament materials. The disc is integrated with a motor-driven mechanism that allows precise angular movement, ensuring that each slot housing a filament material is correctly aligned with the nozzle during the transition. The 90-degree rotation is controlled via a stepper motor or similar actuator, providing smooth and controlled movement to ensure that the selected filament is positioned directly in line with the nozzle and heating element.
[0027] This mechanism is critical for maintaining seamless material changes during multi-material 3D printing operations. When a specific filament is no longer required, the system initiates the rotation of the disc by retracting the current filament and then turning the disc by 90 degrees to present a new slot containing a different filament. The rotation happens in a precise, timed manner to ensure the nozzle remains aligned with the correct filament slot, preventing any misalignment or delays during the transition.
[0028] The ability to rotate the disc by 90 degrees provides a highly efficient solution for multi-material printing, as it allows the system to quickly switch between four different filaments without manual intervention. This significantly reduces downtime and enhances productivity in additive manufacturing processes, enabling operators to switch materials rapidly based on design needs. The precision of the rotating disc system ensures that material transitions are smooth, contributing to a consistent and high-quality output during the 3D printing process.
[0029] In another embodiment, the slots on the rotating disc are strategically positioned to ensure that when the disc is rotated, the selected filament aligns seamlessly with the nozzle for smooth feeding. Each slot is designed to securely hold a different filament, ensuring that it remains in place during rotation and feeding processes. The positioning of the slots is key to minimizing any potential misalignment that could affect filament feeding.
[0030] When the disc rotates, the selected slot is precisely aligned with the nozzle, allowing the filament to pass directly into the heating zone. This alignment is critical, as any deviation could lead to filament jams or inconsistent material flow during extrusion. The smooth alignment is achieved by incorporating precise tolerances in the design of the slots and the disc's rotation mechanism, ensuring that the filament moves effortlessly from the slot to the nozzle.
[0031] Moreover, the slots are spaced in such a way that they prevent overlap or interference between filaments when switching materials. This ensures that only the selected filament is in contact with the nozzle at any given time, maintaining the integrity of the print. The seamless alignment and smooth feeding provided by the slot positioning on the rotating disc improve the overall efficiency and reliability of the multi-material 3D printing process, enabling quick and accurate transitions between different filament types.
[0032] In another embodiment, the control system is designed to actively monitor the type of filament being used and its consumption during the 3D printing process, optimizing the switching between different filaments to enhance operational efficiency. The control system integrates sensors and data processing algorithms that track the length of filament used, the type of material, and the remaining amount available in each slot of the rotating disc. This real-time monitoring is crucial for avoiding material wastage and ensuring seamless transitions between different filaments during multi-material printing operations.
[0033] When the system detects that a filament is nearing depletion, it prepares for an automated switch by identifying the next available slot with the required filament material. The control system also takes into account the properties of each material, such as melting temperature, flow rate, and specific application needs, to adjust the heater settings accordingly before the new filament is engaged. By optimizing these parameters in advance, the system ensures that the transition between filaments occurs smoothly without interrupting the printing process.
[0034] Additionally, the control system utilizes feedback from the sensors to continuously adjust the filament feeding process, maintaining consistent extrusion quality. If a filament type requires particular settings for optimal performance, the control system dynamically adjusts the nozzle's temperature and feed rate, ensuring that the extrusion of different materials remains uniform throughout the print. This intelligent monitoring and optimization capability minimizes downtime associated with filament switching, enhances print quality, and ensures that multi-material printing processes are carried out with high precision and efficiency.
[0035] In another embodiment, the gear mechanism and stepper motor work in tandem to provide precise, coordinated movement of both the nozzle and the rotating disc, thereby enhancing the accuracy of filament extrusion during the 3D printing process. The stepper motor is intricately linked to the gear mechanism, which facilitates vertical movement of the nozzle along the Z-axis. This allows for precise alignment with the selected filament slot on the rotating disc, ensuring that the filament is fed into the nozzle correctly.
[0036] The gear mechanism is designed to convert the rotational motion of the stepper motor into the vertical displacement of the nozzle. This conversion is achieved through a series of gears that multiply the motor's rotation, enabling fine-tuning of the nozzle's position. Such precision is critical, as it allows the nozzle to maintain consistent contact with the filament during feeding, reducing the risk of jams or material flow inconsistencies.
[0037] Moreover, the stepper motor's inherent ability to control rotational angle with high precision allows the system to execute complex movement sequences. For instance, when the system requires a switch from one filament to another, the stepper motor can accurately rotate the disc to the next designated slot while simultaneously adjusting the nozzle's height to match the new slot's position. This synchronized operation minimizes the time between material changes and enhances the overall efficiency of the additive manufacturing process.
[0038] reliable filament extrusion, crucial for achieving intricate designs in multi-material 3D printing applications.
, Claims:1. A multi-filament feeding mechanism for use in additive manufacturing, comprising:
a. a rotating disc having multiple slots, each slot configured to accommodate a different filament material;
b. a nozzle configured for extrusion of filament material, the nozzle being movable in a vertical direction;
c. a heater arrangement coupled to the nozzle for liquefying the filament material before extrusion;
d. a gear mechanism configured to control the vertical movement of the nozzle, allowing precise alignment between the nozzle and the slots on the rotating disc;
e. a stepper motor-driven roller system for feeding filament material through the slots into the nozzle;
f. a control system configured to automate the rotation of the disc, allowing rapid switching between filament materials without manual intervention.
2. The mechanism of claim 1, wherein the rotating disc allows accommodation of more filament materials for increased flexibility in material selection.
3. The mechanism of claim 1, wherein the gear mechanism enables precise vertical movement.
4. The mechanism of claim 1, wherein the nozzle's vertical movement is controlled by a stepper motor, facilitating accurate filament extrusion during the 3D printing process.
5. The mechanism of claim 1, further comprising a filament retraction system that retracts the currently engaged filament.
6. The mechanism of claim 1, wherein the heater arrangement is capable of adjusting the temperature.
7. The mechanism of claim 1, wherein the slots are positioned to ensure seamless filament feeding and alignment with the nozzle when the disc is rotated.
8. The mechanism of claim 1, further comprising a control system configured to monitor filament usage and material types, optimizing the switching process between different filaments.
9. The mechanism of claim 1, wherein the gear mechanism and stepper motor provide coordinated movement of the nozzle and disc, enhancing precision in filament extrusion.

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