Description:The Polymer Filament Fabrication System for In-Situ Fabrication and Spooling of Reinforced Filament emerges as a response to the growing demand for high-quality, durable, and reinforced filaments in the field of Poly-Ex fabrication. This system addresses the limitations of conventional filament production methods by introducing an innovative approach that enhances the strength and performance of filaments through in-situ reinforcement.
The Polymer Filament Fabrication System (100) consists of three units: Reinforced filament Making Unit (200), Water Bath Unit (300), Spooling Unit (400), and Poly-Ex fabrication unit (500).
The Reinforced filament Making Unit (200) consists of motor (201), gears (202), hopper (203), dual shape inlet tube (204), cylindrical chambers (205), heaters (206), nozzles (207), base (208), and filament drawing screws (209).
The Base (208) of invention serves as the foundation and support for the entire Reinforced filament Making Unit (200). Base (208) is a sturdy and rigid structure that ensures stability and provides a secure platform for the Reinforced filament Making Unit (200) components and operations. It is constructed using steel, cast iron & heavy-duty alloys. The Base (208) is assembled by connecting rods using nuts and bolts. This component is crucial as the entire Reinforced filament Making Unit (200) relies on it and it acts as the foundation for the system. On which every component is mounted, among which one is motor (201). The Reinforced filament Making Unit (200) utilizes an electric motor (201). The motor (201) provides rotational motion to the gears (202). It operates on the principles of electromagnetism. When an electric current flows through a coil or filament within a magnetic field, it generates a force that causes the motor's (201) rotor (the rotating part) to turn. Electric motor (201) is used in invention has high efficiency, reliability, and controllability. From the motor (201) rotation is transferred to the gears (202). Gears (202) are connected to the motor (201) and their main purpose in this system is to transfer rotational motion to the filament drawing screws (209) located within cylindrical chambers (205). Gears (202) are mechanical devices consisting of toothed wheels that mesh to transmit motion and torque. Gears (202) are employed to change the speed, direction, and torque of rotational motion in Reinforced filament Making Unit (200). Reinforced filament Making Unit (200) consists of four Gears (202) interlinked to transfer rotational motion from one gear to another, ultimately driving the filament drawing screws (209) inside the cylindrical chambers (205).
The solid pallets are poured into the system through the hopper (203). On the Cylindrical chambers (205) the Hopper (203) is mounted. Hopper (203) is utilized in the Reinforced filament Making Unit (200) for dispensing bulk materials. It features a funnel-shaped design with a wide opening at the top and a narrow outlet at the bottom. This funnel-shaped design facilitates smooth and even flow of the material towards the outlet. In this Reinforced filament Making Unit (200), solid pallets of material such PLA, TPU, ABS, PEEK, PMMA, TPE, and Ninja flex along with carbon fibers or MWCNTs, are poured into the Hopper (203). These materials offer a wide range of properties, such as flexibility, strength, heat resistance, and transparency, enabling the production of the filament.
From the Hopper (203) the solid pallets material flows to cylindrical chambers (205) through the dual shaped inlet tube (204). Below Hopper (203) there is a Dual-shaped inlet tube (204) that is connected to the Hopper (203) and ensures equal distribution of the material to both cylindrical chambers (205).
The Cylindrical chamber (205) is a hollow shaped cavity that consists of heaters (206), filament drawing screws (209), and Nozzle (207), each serving a specific role in the filament drawing process. There is a total of two cylindrical chambers (205) in the Reinforced filament Making Unit (200) for dual extrusion and high efficiency.
Heaters (206) are used to melt the solid pallets to liquid form. Heaters (206) convert electrical energy into heat energy, raising the temperature of the material inside the cylindrical chambers (205). By melting the solid material into a liquid state, the desired product in filament form can be obtained. Two Heaters (206) are installed over each cylindrical chamber (205) to facilitate this process.
Inside the cylindrical chambers (205) there are filament drawing screws (209). Filament drawing screws (209) play a crucial role in filament drawing, which involves pulling the material through a series of progressively smaller dies to reduce its diameter and shape it into filament. Filament drawing Screws (209) are specialized components used in Reinforced filament Making Unit (200) to ensure smooth and controlled movement of the filament through the drawing process. They work in conjunction with the filament drawing Screws (209) to apply pressure and reduce the diameter of the filament while maintaining its shape. These Filament drawing Screws (209) have a tapered or conical design, gradually reducing in diameter along their length. The helical ridges or threads on the Filament drawing Screws (209) grip and pull the filament through the dies as the Filament drawing Screws (209) rotate. They are made from high-strength materials to withstand the high forces and abrasion encountered during the filament drawing process. The Filament drawing Screws (209) are precision-engineered to align properly with the drawing dies, minimizing friction and maximizing efficiency. Through the Filament drawing Screws (209) on the outlet of the cylindrical chambers (205) the Nozzle (207) are mounted. There are total of 2 nozzles mounted on each of the cylindrical chambers (205).
Nozzle (207) are connected to achieve the desired diameter for the filament required. The Nozzles (207) are detachable, allowing for customization based on the required filament diameter. For instance, if a filament with a diameter of 1.75mm is needed, a nozzle (207) with an outlet diameter of 1.75mm would be attached or if diameter of 2.80mm is needed that can be achieved by doing same. Nozzles (207) are utilized to reduce the diameter of a material, and different options are available depending on the specific requirements of the application.
The water bath unit (300) consists of open grooves (301), Support panels (302), Close grooves (303), Water Bath tank (304), Water Storage chamber (305), Water tap pipe (306), water tap (307), and Water pump (308).
From the Reinforced filament Making Unit (200) the filament moves to a water bath unit (300) through the open grooves (301) marked on the Water bath tank (304). The Water Storage chamber (305) serves as a crucial storage unit for water, located beneath the Water Bath tank (304). It supplies water to the water bath tank (304) above, playing a vital role in the system's functioning.
The Water Bath tank (304) receives water from the water storage chamber (305), which is essential to the system's operation. As the hot filament-shaped material exits the cylindrical chamber (205) through the nozzle (207), is inserted into the close grooves (303) of the support panels (302) through open grooves (301). Throughout this process, the filament-shaped material is in a hot and liquid state and the water bath provided to it solidifies and strengthens it. This process is known as quenching, water quenching is used to achieve specific material properties. When hot polymer is rapidly cooled, it undergoes a process called phase transformation, where its structure changes to become harder and stronger. This is due to the formation of a fine-grained microstructure, which enhances the material's mechanical properties. The process of water quenching involves passing the hot filament from a water bath tank (304) to achieve rapid cooling. The temperature gradient created by the rapid cooling causes the material's outer layers to solidify and harden quickly. This differential cooling will result in beneficial properties such as increased hardness, strength, and wear resistance. Below the Water Bath tank (304) the Water Storage chamber (305) is placed. The Water Storage chamber (305) and Water Bath tank (304) are integral components of the water bath unit (300). From the water storage chamber (305) the Water Bath tank (304) receives water to solidify and reinforce the hot filament-shaped material.
The panels (302) situated above the Water Bath tank (304) serve as support and provide guidance for the material, with circular closed grooves (303) created on both sides of each panel in a straight line according to the open groove on the water bath tank (301). Three panels (302) of this type are uniformly attached along the length of the tank to provide support and guide the material safely without causing damage. These panels (302) are fabricated by Poly-Ex Fabricator (500).
To fill water in the Water Bath tank (304), Water Tap (307) is used and is mounted on the Water storage chamber (305). It is a device used to control the flow of water from the Water Storage chamber (305) to the water bath tank (304). It is installed to provide water from the Water pump (309) installed in the Water Storage chamber (305), which provides the necessary pressure for the water to move from water storage chamber (305) to water bath tank (304). In the upper tank the water from the Water pump (309) moves through water tap (307) after passing through water tap pipe (306). Finally, the solid filament-shaped material exits from the grooves for the process of spooling by the spooling unit (400).
The Spooling unit (400) consists of Spool guiding mechanism (404) and Spool Holding mechanism (405). The spool guiding mechanism (404) is used to guide the filament to spool providing continuous and distributed spooling. This system consist of Stepper motor (401) U-shaped bearing holder (402), smooth roller (403), spooling guider smooth Rod (406), base (407), bearing (408), and spooling guider threaded Rod (409), While Spool Holding mechanism (405) used to hold the spool and it provides continuous and uniform rotation to spools holding rods and rotation is done thorough spools rotating gear (410), Intermediary gear (411), and motor (412).
The parts of spooling unit (400) working together to facilitate the movement and distribution of filament.
Spooling unit has a robust Base (407) providing support to all the parts involved. Two Stepper motors (401) are connected to bearings (408), and these bearings (408) are fixed inside a U-shaped bearing holder (402). Bearing (408) is a mechanical component that is used to reduce friction between moving parts and facilitate smooth rotation. It consists of two main components: the inner ring and the outer ring. Between these rings, there are rolling elements as balls that enable the relative motion between the inner and outer rings. The purpose of the bearings (408) is to enable to transfer the smooth rotation of the Stepper motor (401) to the smooth rollers (403). A Stepper motor (401) is an electric motor that converts digital pulses into precise mechanical movements. It operates by moving in discrete steps or increments, allowing for accurate positioning and control. Stepper motor (401) finds widespread use in applications that require precise movement and positioning in the system.
To provide support & rotation to the smoot rollers (403) the u-shaped bearing holder (402) is used. The pair of rollers (402) are sandwiched between the u-shaped bearing holder (402). These Rollers (403) are driven by the Stepper motors (401) and apply forces to facilitate the forward movement of the filament. The filament itself is manually stretched from Reinforced filament Making Unit (200) to Spooling Unit (400) by passing it between these Rollers (403). The presence of the Rollers (403) ensures that the load on the filament is distributed evenly, minimizing the risk of filament breakage.
Now for spooling the filament spool holding mechanism (405) are used, to achieve uniform distribution of the filament. A spooling Guiding Mechanism (404) is employed. This mechanism allows for lateral movement, ensuring that the filament is distributed evenly across the spools of spool holding mechanism (405). This lateral movement helps prevent the filament from accumulating unevenly or causing entanglements. In the spooling Guiding Mechanism (404), there is a spooling Guider smooth Rod (406) that allows the spooling guider mechanism (404) to slide smoothly. The spooling guider threaded rod (409) is connected to another Stepper motor (401). The purpose of this Stepper motor (401) and the Guider Threaded Rod (410) is to provide a to-and-fro motion to the spooling guiding mechanism (404). The filament is a passed through a circular groove located at the top of the spooling guiding mechanism (404). By moving the spooling Guider Threaded Rod (410) left or right, the filament is guided accordingly, contributing to the uniform distribution of the filament on the spools of spool holding mechanism (405). The spools of spool holding mechanism (405) are securely attached on either side of the spooling rotating gear shaft. The Spools rotating gear (410) is providing the rotational motion to the spooling rotating gear shaft which is resulting in rotation of spools of spool holding mechanism (405) and spooling of the filament.
This rotation is given to the Spools rotating gear (410) by the motor (412) which is positioned beneath the intermediary gear (411), serves as the driving force for the spools of spool holding mechanism (405). When the motor (412) is activated, it generates rotary motion that is transferred to the gear (411). This gear (411), in turn, acts as an intermediary component, transmitting the rotary motion to the spools rotating gear (410).
As the Spools rotating gear (410) rotates, it imparts the same rotary motion to spools of spool holding mechanism (405) rotating gear shaft causing it to rotate. The spools of spool holding mechanism (405), being firmly connected to the spools rotating gear shaft consequently rotate. The rotation of the spools of spool holding mechanism (405) is calculated and controlled to achieve the desired winding rate for the filament. To initiate the filament winding process, the filament is fed into the spools of spool holding mechanism (405). As the spools of spool holding mechanism (405) rotate, driven by the motor (412) and the intermediary Spools rotating gear (411) and rotating gear (410), the filament is gradually wound onto the designated spool of spool holding mechanism (405). The calculated rate of rotation ensures a consistent and controlled winding of the filament onto the spools of spool holding mechanism (405), facilitating efficient and precise filament winding operations. Overall, the spooling unit (400) is designed to ensure the smooth and controlled movement of filament while maintaining uniform distribution on the spools of spool holding mechanism (405).
The Poly-Ex fabrication unit (500) consists of frame (501), vertical columns (502), carriage (503), extruder (504), print bed (505), effector (506), print head (507), nozzle (508), control board (509)
The frame (501) is the structural backbone of the poly-ex fabrication unit (500), providing stability and rigidity. It typically consists of aluminum extrusions or other sturdy materials that ensure the printer's stability during operation. The Poly-Ex fabrication unit (500) employs three vertical columns (502) that are strategically positioned in a triangular arrangement. These columns serve as the primary support structure and guide the movement of the printer's carriage (503). The carriage (503) is a platform that moves along the vertical columns (502). It carries the extruder (504) and the print bed (505), enabling them to position themselves precisely within the printer's print area. The carriage (503) is designed to move smoothly and accurately to achieve high-quality prints. The effector (506) is located at the lower end of the vertical columns (502) and is directly connected to the carriage (503). It acts as a mechanism for transmitting the movement from the carriage (503) to the extruder assembly (504). The print bed (505) is the surface where the printed object is built layer by layer. It can be heated to improve adhesion and prevent warping of the printed material. The print bed (505) is typically adjustable to allow for leveling and alignment. The extruder (504) is responsible for feeding the filament into the print head (507) and melting it for deposition. It consists of a motor-driven gear system that pushes the filament through a heated nozzle (508), forming the molten material that is deposited onto the print bed (505). The print head (507) houses the extruder nozzle (508). It moves in three dimensions (X, Y, and Z axes) under the control of the printer's firmware. The print head deposits the molten filament onto the print bed in a controlled manner, following the instructions from the slicing software. Poly-Ex fabrication Unit (500) employ multiple stepper motors for precise control of movement. The motors are typically connected to the vertical columns and the effector, allowing them to move the carriage and the print head in a synchronized manner. Each motor corresponds to a specific axis (X, Y, or Z) and receives instructions from the printer's control system.
The control board (509) serves as the brain of the Poly-Ex fabrication Unit (500). It receives commands from the slicing software and translates them into instructions for the stepper motors. The control board (509) also manages other components, such as the heated bed and extruder temperature control, ensuring proper coordination and synchronization during printing.
The Poly-Ex fabrication Unit (500) utilizes three identical arms that extend vertically from the top of the vertical columns (502) down to the effector (506). These arms are typically made of lightweight and rigid materials such as carbon fiber or aluminum. They are positioned at equal angles around the effector (506), forming an equilateral triangle. First Arm (510) is typically positioned at the front of the printer, forming one side of the equilateral triangle. Second Arm (511) is usually located on the left-hand side of the printer, forming another side of the equilateral triangle. Third Arm (512) commonly positioned on the right-hand side of the printer, completing the equilateral triangle with the other two arms.
, Claims:We claim:
1. A polymer filament fabrication system (100) for in-situ fabrication and spooling of reinforced filament comprising:
? a reinforced filament making unit (200) to produce high-quality reinforced filaments;
? a water bath unit (300) for the purpose of solidification of the hot filament-shaped material;
? a spooling unit (400) to firmly hold the spool for filament winding at a constant rate; and
? a poly-ex fabrication unit (500) to fabricate the parts of water bath unit (300) and spooling unit (400);
characterised in that, solid pallets of polymers are melted in a reinforced filament-making unit (200) and extruded out in semi-solid wire form, which is then solidified after passing through the water bath unit (300), and then winding of filament takes place on the spooling unit (400).

2. The polymer filament fabrication system (100) as claimed in claim 1, wherein the reinforced filament making unit (200), consists of motors (201), gears (202), hoppers (203), dual shape inlet tube (204), cylindrical chamber (205), heaters (206), nozzles (207), base (208), and filament drawing screws (209) for the functions of material melting, controlled filament drawing, and diameter reduction.

3. The polymer filament fabrication system (100) as claimed in claim 1, wherein the water bath unit (300) consists of open grooves (301), support panels (302), close grooves (303), water bath tank (304), water storage chamber (305), water tap pipe (306), water tap (307), and water pump (308).

4. The polymer filament fabrication system (100) as claimed in claim 1, wherein the spooling unit (400) consists of spool holding mechanism (405) and spool guiding mechanism (404), through winding and storing the filament onto a spool uniformly along the surface.

5. The polymer filament fabrication system (100) as claimed in claim 1, wherein the poly-ex fabrication unit (500) consist of frame (501), vertical columns (502), carriage (503), extruder (504), print bed (505), effector (506), print head (507), nozzle (508), control board (509).