OMNI3D has recently been granted a United States patent for the extruder system used in their Factory 2.0 NET industrial 3D printer. This system was designed by OMNI3D in response to the need for strong, precise, & resistant models built at greater dimensions. Typically, comparable industrial 3D printers use heat sinks to remove heat from the body of the printer motor. Alternatively, OMNI3D’s liquid cooling system eliminates the need for heat sinks, which reduces the overall weight of the printer head and allows for maximum speed & efficiency.
The main task for me, as the designer of this solution, was to improve the working conditions for the knurled-filament-filament clamp system. These elements had to work at a sufficiently low temperature to ensure the right force for pressing the filament into the heated head. To improve these parameters, we used a cooling system that receives thermal energy from the extruder body, and transmits energy through the liquid pipes to the cooler, which ejects excess heat energy into the environment, and thus improves the operating conditions of the previously mentioned system. Thanks to the use of such a solution, it was also possible to stabilize the operating parameters of the extruder motor and it made it possible to resign from the head heat sink. In this case, the heat sink function was taken over by the extruder body. Thanks to this, the extruder became compact, and at the same time allowed for printing for many hours in a heated printing chamber
The main task when creating this patent was to improve the working conditions for the knurled-filament-clamp system. These elements had to work at a sufficiently lower temperature to ensure the right force for pressing the filament into the heated head. To improve these parameters, Omni3D used a cooling system that receives thermal energy from the extruder body, transmits energy through the liquid to the cooler, which "ejects” excess heat energy to the environment, and thus improves the operating conditions of the previously mentioned system. It was also possible to stabilize the operating parameters of the extruder motor and to resign from the head heat sink. In this case, the heat sink function was taken over by the extruder body. The extruder became compact, and at the same time, the new system, allowed for printing for many hours in a heated printing chamber. By eliminating heat sinks, the head weight of the device is reduced, which in turn enables printing with greater acceleration and maximum speed.
Reduction of the temperature of filament on the path to the liquefaction zone minimize the risk of softening at the wrong stage. Cooling system also significantly improved the operation of the motor.
Patent includes also new solution of modular head assembly system. It makes easy to change the heads and minimize errors that could affect printing. It is specifically important for the proper use of the double print head, which allows to print at Omni3D solution from 2 types of filaments (base and support) at the same time.
The use of a double head system determines and explains the importance of the patented Omni3D solution, which provides to:
Omni3D Cooling System™
The extruder direct cooling system effectively reduces the temperature of the filament’s path by 40 – 60 ° C. This prevents the filament from reaching its softening point (called the Deflaction Point), and increases its stiffness, which ultimately improves printing control, increases speed, and refines process stability over long periods. The unique construction of this type of extruder also shortens the path between the filament feeding wheel and the nozzle to ensure more precise feeding of the filament to the softening zone.
OMNI3D’s patented extruder system is also able to calculate the speed at which the material is fed, the amount of material melted in the nozzle, and the amount of material extruded out of the nozzle. This is done with the help of one of OMNI3D’s unique points known as Omni3D Filament Flow Control.
Omni3D Filament Flow Control™
Omni3D’s patented solution is able to improve the accuracy of printed parts by providing greater control over the amount of filament fed. The print head implements filament flow control sensors, which are sensors that compare the amount of filament fed with that set in the gcode. With the help of special encoders, the system counts the amount of filament fed and compares it with the given amount in .gcode.
When the discrepancies are too large, the printer informs the operator about it. This ensures precision and dimensional repeatability from your prints each time. Omni3D Filament Flow Control™ helps users manage their print quality, budget, time and nerves by directly detecting a lack of filament, jams, and other undesirable activities that can occur with filament during printing. That is why the systems that are successively implemented by Omni3D are dedicated to companies that focus on quality, reliability and safety.
To learn more about OMNI3D’s United States patent, visit OMNI3D’s Blog Page.
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The full description of the patented solution can be found under
patent EU/PL: 230139/PL230139B1
patent USA: US 2019/0184633 A1