Awards

Problems

• Jam: Heat can conduct up into the cold zone, swelling the filament and jamming the print head
• Leak: Low viscosity melted filament can leak through poorly sealed components, especially threads
• Seize: Thermal cycling can seize threaded components eliminating the ability to rebuild the print head, while anti-seize can clog the nozzle

Solution

• Intent: Concentrate heat at the end of the filament while preventing transfer upwards in the print head
• Components: Nozzle, Heater, Insulator, Cooler
• Design: Slim nozzle with face-to-face heater connection (without threads), insulator immediately above it with fins and cooling fans
• Operation: Retract filament during print head travel to keep the heat from heat-soaking the filament

Problems

• Warp: Open frames convect heat out of the printer causing large prints to warp
• Airflow: Uncontrolled ambient airflow cools layers unevenly causing splits and weak layer adhesion
• Safety: Users are exposed to heaters, moving components, and toxic plastic fumes

Solution

• Intent: Hold stable chamber temperature so prints are dimensionally and materially sound
• Components: Frame, Panels, Door
• Design: Cabinet fully encloses all heated and moving components
• Operation: Close the door during the print to hold chamber heat; open for part removal and maintenance