Aspects and embodiments disclosed herein relate to device and systems for varying the filament path length in a three-dimensional printer and managing the feed rate of said filament.
In accordance with an aspect, there is provided a three-dimensional printer for the additive manufacturing of a part. The printer may include a build platen, a pre-extrusion system, and a print head located downstream of the pre-extrusion system and configured to receive and deposit a filament. The print head may include a receiving section configured to receive the filament. The receiving section can include an inlet through which the filament is threaded. The print head may include an outlet through which the filament is deposited onto the build platen or a previously added layer of a part. The print head further can include a feeding mechanism constructed and arranged to feed the filament into the outlet. The print head additionally can include a path length adjustment system positioned on the print head disposed between the pre-extrusion system and the feeding mechanism. The path length adjustment system can be constructed and arranged to create slack in the filament being delivered from the pre-extrusion system.
In some embodiments, the path length adjustment system of the print head may include a housing connected to the print head and comprising an open side and a central space. The path length adjustment system may include a sliding component constructed and arranged to translate along the open side of the housing, the sliding component may have a first portion that sits within the central space and a second portion that projects away from the open side. The path length adjustment system further may include an inner bushing positioned within the first portion of the sliding component and having a diameter adapted to pass a filament therethrough. The sliding component adjusting a path length of the filament in response to a pressure on the filament during a printing process.
In some embodiments, the sliding component includes a component constructed and arranged to provide a bias force in an opposing direction to a filament feed. In some embodiments, the sliding component includes a component constructed and arranged to provide a bias force aligned with a filament feed direction. In specific embodiments, the component constructed and arranged to provide a bias force is a spring. For example, one or more springs may be coupled to one or both of the sliding component and the housing. In specific embodiments, the component constructed and arranged to provide a bias force is a magnet positioned on the sliding component opposing a magnet positioned in the housing.
In some embodiments, the second portion of the sliding component may include a magnet disposed along a feed path of the filament through the path length adjustment system. The path length adjustment system can provide for a path length adjustment range of about 0.5 mm to about 1.5 mm, e.g., about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, or about 1.5 mm.
In some embodiments, the sliding component is manufactured from a polymer.
In some embodiments, the path length adjustment system of the print head may include a central body having a top, a bottom, and a passage therethrough. The central body can be aligned with the filament direction through the print head. The path length adjustment system can include a first flexure having a first end connected to the top of the central body and a second end connected to the print head. The path length adjustment system further may include a second flexure having a first end connected to the bottom of the central body and a second end connected to the print head. The central body can pivot between the first flexure and second flexure to adjust a path length of the filament in response to a pressure on a filament during a printing process.
In some embodiments, the central body may include a magnet disposed along a feed path of the filament through the path length adjustment system.
In some embodiments, the central body may provide for a path length adjustment range of about 0.5 mm to about 3.0 mm, e.g., about 0.5 mm to about 3.0 mm, about 0.75 mm to about 2.75 mm, about 1.0 mm to about 2.5 mm, about 1.25 mm to about 2.25 mm, or about 1.5 mm to about 2.0 mm, e.g., about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, or about 3.0 mm.
In any embodiment described herein, the print head may include a sensor constructed and arranged to measure the linear position of the path length adjustment system. For example, the sensor may interact with the magnet located on the path length adjustment system to provide an output corresponding to a metric for the length of the path length of the filament.
In further embodiments, the printer may include a controller constructed and arranged to direct one or both of the feed mechanism and the pre-extruder to feed the filament to the print head. In certain embodiment, the controller may be configured to adjust the feed rate of the printer at one or both of the pre-extrusion system and feeding mechanism based on an output from the sensor in the path length adjustment system.
In accordance with an aspect, there is provided a device for adjusting a filament path length in a three-dimensional printer, comprising a movable component having a passage therethrough attached to a print head, the passage sized to pass the filament. The movable component may adjust a path length of the filament in response to a pressure on the filament during a printing process by moving along a long axis of the filament.
In some embodiments, wherein the movable component may be disposed within an open sided housing that permits the movable component to translate within the housing. The movable component may have a first portion that sits within the housing and a second portion that projects away from the open side of the housing. In further embodiments, the movable component may include an inner bushing positioned within the first portion of the sliding component and having a diameter adapted to pass a filament therethrough.
In some embodiments, the movable component may include a central body having a top, a bottom, and a passage therethrough, a first flexure having a first end connected to the top of the central body and a second end, and a second flexure having a first end connected to the bottom of the central body and a second end. The central body may be aligned with the filament direction through a print head of the three-dimensional printer.
In some embodiments, the movable component, e.g., a sliding component, includes a component constructed and arranged to provide a bias force in an opposing direction to a filament feed. In some embodiments, the movable component, e.g., a sliding component, includes a component constructed and arranged to provide a bias force in a direction aligned to a filament feed. In specific embodiments, the component constructed and arranged to provide a bias force is a spring. In specific embodiments, the component constructed and arranged to provide a bias force is a magnet positioned on the sliding component opposing a magnet positioned in the housing.
In some embodiments, the movable component may provide for a path length adjustment range of about 0.5 mm to about 3.0 mm, e.g., about 0.5 mm to about 3.0 mm, about 0.75 mm to about 2.75 mm, about 1.0 mm to about 2.5 mm, about 1.25 mm to about 2.25 mm, or about 1.5 mm to about 2.0 mm, e.g., about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, or about 3.0 mm.
In some embodiments, the movable component is manufactured from a polymer. In some embodiments, the movable component may include a magnet disposed along a feed path of the filament through the path length adjustment system.
In accordance with an aspect, there is provided a device for adjusting a path length in a three-dimensional printer. The device may include a housing connected to a print head of a three-dimensional printer. The housing may include an open side and a central space. The device may include a sliding component constructed and arranged to translate along the open side of the housing. The sliding component may have a first portion that sits within the central space and a second portion that projects away from the open side. The device further may include an inner bushing positioned within the first portion of the sliding component and having a diameter adapted to pass a filament therethrough. The sliding component may adjust a path length of the filament in response to a pressure on the filament during a printing process.
In accordance with an aspect, there is provided a device for adjusting a path length in a three-dimensional printer. The device may include a central body having a top, a bottom, and a passage therethrough. The central body of the device may be aligned with the filament direction through a print head of the three-dimensional printer. The device may include a first flexure having a first end connected to the top of the central body and a second end. The second end of the first flexure may be connected to the print head. The device further may include a second flexure having a first end connected to the bottom of the central body and a second end. The second end of the second flexure may be connected to the print head. The central body may pivot between the first flexure and second flexure to adjust a path length of the filament in response to a pressure on a filament during a printing process.
The accompanying drawings are not drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in the various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
The features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended that the appended claims cover all systems and methods falling within the true spirit and scope of the disclosure. As used herein, the indefinite articles “a” and “an” mean “at least one” or “one or more.” Similarly, the use of a plural term does not necessarily denote a plurality unless it is unambiguous in the given context. Words such as “and” or “or” mean “and/or” unless specifically directed otherwise. In this application, the terms “comprising” and “including” may be understood to encompass itemized components or steps whether presented by themselves or together with one or more additional components or steps. Unless otherwise stated, the terms “about” and “approximately” may be understood to permit standard variation as would be understood by those of ordinary skill in the art. Where ranges are provided herein, the endpoints are included. As used in this application, the term “comprise” and variations of the term, such as “comprising” and “comprises,” are not intended to exclude other additives, components, integers or steps.
As used in this application, the terms “about” and “approximately” are used as equivalents. Any numerals used in this application with or without about/approximately are meant to cover any normal fluctuations appreciated by one of ordinary skill in the relevant art. In certain embodiments, the term “approximately” or “about” refers to a range of values that fall within 25%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less in either direction (greater than or less than) of the stated reference value unless otherwise stated or otherwise evident from the context (except where such number would exceed 100% of a possible value).
Many methodologies described herein include a step of “determining.” Those of ordinary skill in the art, reading the present specification, will appreciate that such “determining” can utilize or be accomplished through use of any of a variety of techniques available to those skilled in the art, including for example specific techniques explicitly referred to herein. In some embodiments, determining involves manipulation of a physical sample. In some embodiments, determining involves consideration and/or manipulation of data or information, for example utilizing a computer or other processing unit adapted to perform a relevant analysis. In some embodiments, determining involves receiving relevant information and/or materials from a source. In some embodiments, determining involves comparing one or more features of a sample or entity to a comparable reference.
As used herein, the term “substantially,” and grammatic equivalents, refer to the qualitative condition of exhibiting total or near-total extent or degree of a characteristic or property of interest. One of ordinary skill in the art will understand that chemical phenomena rarely, if ever, go to completion and/or proceed to completeness or achieve or avoid an absolute result.
Among other things, the present disclosure provides composite objects including an internal component made from a printable material and an outer component formed from a castable material, i.e., a polymer or resin. Methods for manufacturing these types of composite objects are also disclosed herein. Various embodiments according to the present disclosure are described in detail herein.
Additive manufacturing, sometimes more generally known as three-dimensional printing, refers to a class of technologies for the direct fabrication of physical products from a three-dimensional computer model by a layered manufacturing process. In contrast to material removal processes in traditional subtractive manufacturing, the three-dimensional printing process adds material. In additive manufacturing, 3D parts are manufactured by adding layer-upon-layer of material. For example, an additive manufacturing-based 3D printing device can create a 3D part, based on a digital representation of the part, by depositing a part material along toolpaths in a layer-by-layer manner. This process can enable the direct printing of products with extremely complex geometry.
Fused Deposition Modeling (FDM) also referred to as Fused Filament Fabrication (FFF) is an example of additive manufacturing technology used for modeling, production, and prototyping. In an FDM, FFF additive manufacturing process, a moving print head extrudes a filament of material onto a print bed or to an object being printed. The print head and/or the print bed can move relative to each other under computer control to define the printed object. Additive manufacturing of a layer generally involves slicing a two-dimensional layer into a series of shells, that is beads, lines, or shells that are stacked on top of one another (that is, along the z-axis) forming a digital representation of the intended part. The printing of a layer is typically done shell-by-shell on a build plate or print bed until the one or more shells (i.e., the plurality of shells) are complete, e.g., by incrementing the position of the print head relative to the substrate along one or more print axes. For example, each two-dimensional layer may have a number of shells lining a contour, such as a perimeter of a wall. This process can then be repeated to form an object, i.e., a three-dimensional part, resembling the digital representation. The process of depositing or extruding shells is typically in a machine-controlled manner according to slicing parameters. Additionally, for example, printing of subsequent shells may include extruding by tracing along a contour or path defined by a prior printed shell. A result of such a process can be a repeatable and consistent extrusion. Moreover, each two-dimensional layer may have a different fill pattern filling the interior of the part. Additionally, a fill pattern may be deposited between an inner and an outer perimeter of a wall.
In a fused deposition additive manufacturing system, a three-dimensional part or model may be printed from a digital representation of the three-dimensional part in a layer-by-layer manner by extruding a flowable part material along toolpaths.
The print head can move in two dimensions to deposit one horizontal plane of material to form a layer of the object being printed. Then, the print head or the print bed can be moved vertically by a small amount to begin another horizontal plane of material to form a new layer of the object. The part material is extruded through an extrusion tip carried by a print head of a three-dimensional printing apparatus, device, or system. Part material is deposited as a sequence of roads on a substrate in a build plane. A layer, for example, a first layer of a printable material is deposited (i.e., extruded) onto the build surface. That is, for example, a horizontal layer is printed with movement in the X-Y axis. Once this first horizontal layer is completed, a height adjustment is made in the Z axis. Another horizontal layer of is printed with movement in the X-Y axis. Once the next horizontal layer is completed, another height adjustment is made in the Z axis. This process continues, for each layer until the object is completed.
For a three-dimensional printer to maintain consistent operation, the tension in the material being printed can be managed. In general, a filament has to have sufficient tension such that the filament does not fold over and jam the feeding mechanism but cannot be so taught that the filament cannot be fed to the print head. One configuration to manage the tension or slack in a filament being printed is through the use of a “slack box” installed at a suitable location in the filament feed path that provides for minute adjustments in the tension and path length as the filament is fed to the print head.
Existing slack management systems can present a number of issues when using filaments that are sensitive to the surrounding environment. For example, certain filament materials, e.g., nylon and carbon fiber composites, are hygroscopic and are subject to oxidation under ambient conditions. Under these conditions, a portion of a filament to be printed would likely have to be purged from the print head, which would result in the use of excess material and ultimately increase costs. Sealed slack management systems, e.g., systems containing devices for controlling the environment, e.g., humidity, around the filament being printed, are often cumbersome to use and maintain and generally require heat and purge gas supplies, increasing costs and maintenance. It is an object of the present disclosure to provide for a slack management system, i.e., devices for adjusting the filament path length of a three-dimensional printer, that are unsealed and minimize the length of filament exposed to the ambient environment via positioning the path length adjusting device on the print head.
In certain non-limiting embodiments, this disclosure describes devices for adjusting the path length of a three-dimensional printer and printer systems incorporating the same. An embodiment of a three-dimensional printer is illustrated in
In some embodiments, such as illustrated in
The controller may be implemented using one or more computer systems. The computer system may be, for example, a general-purpose computer such as those based on an Intel CORE®-type processor, an Intel XEON®-type processor, an Intel CELERON®-type processor, an AMD FX-type processor, an AMD RYZEN®-type processor, an AMD EPYC®-type processor, and AMD R-series or G-series processor, or any other type of processor or combinations thereof. Alternatively, the computer system may include programmable logic controllers (PLCs), specially programmed, special-purpose hardware, for example, an application-specific integrated circuit (ASIC) or controllers intended for analytical systems. In some embodiments, the controller may be operably connected to or connectable to a user interface constructed and arranged to permit a user or operator to view relevant operational parameters of the printer 100, adjust said operational parameters, and/or stop operation of the printer 100 as needed. The user interface may include a graphical user interface (GUI) that includes a display configured to be interacted with by a user or service provider and output status information of the three-dimensional printer.
The controller can include one or more processors typically connected to one or more memory devices, which can comprise, for example, any one or more of a disk drive memory, a flash memory device, a RAM memory device, or other device for storing data. The one or more memory devices can be used for storing programs and data during operation of the three-dimensional printer. For example, the memory device may be used for storing historical data relating to the parameters over a period of time. Software, including programming code that implements embodiments of the invention, can be stored on a computer readable and/or writeable nonvolatile recording medium, and then typically copied into the one or more memory devices wherein it can then be executed by the one or more processors. Such programming code may be written in any of a plurality of programming languages, for example, ladder logic, Python, Java, Swift, Rust, C, C#, or C++, G, Eiffel, VBA, or any of a variety of combinations thereof.
In general, a path length adjustment device attached to the print head of a three-dimensional printer includes a movable component having a passage therethrough that is sized to pass the filament. The movable component can adjust a path length of the filament in response to a pressure on the filament during a printing process by moving along a long axis of the filament. Without wishing to be bound by any particular theory, the movable component of the path length adjustment device provides for an interruption in the feed path of the filament being deposited by the print head. The movable component provides for the buildup of slack in the filament at the opening of the movable component. When the feed mechanism is directed to deposit filament, the slack in the filament provides for smooth motion of the filament, reducing tension on the filament and potential breaking of the filament during printing from the forces applied by the feed mechanism. The motion of the movable component can be synchronized to one or more other components of the three-dimensional printer, e.g., one or both of the pre-extrusion system or the feed mechanism.
A path length adjustment device includes a housing connected to a print head in a three-dimensional printer, the housing comprising an open side and a central space, a sliding component e.g., a movable component, constructed and arranged translate along the open side of the housing, and an inner bushing positioned within the first portion of the sliding component and having a diameter adapted to pass a filament therethrough. The sliding component includes a first portion that sits within the central space and a second portion that projects away from the open side. In operation, the sliding component adjusts a path length of the filament in response to a pressure on the filament during a printing process.
In other embodiments, a path length adjustment device includes a central body having a top, a bottom, and a passage therethrough, the central body, e.g., a movable component, aligned with the filament direction through a print head of the three dimensional printer, a first flexure having a first end connected to the top of the central body and a second end, and a second flexure having a first end connected to the bottom of the central body and a second end. In this configuration, the central body pivots between the first flexure and second flexure to adjust a path length of the filament in response to a pressure on a filament during a printing process.
In some embodiments, the path length adjustment system, e.g., the movable component of the path length adjustment system, provides for a path length adjustment range of about 0.5 mm to about 3.0 mm, e.g., about 0.5 mm to about 3.0 mm, about 0.75 mm to about 2.75 mm, about 1.0 mm to about 2.5 mm, about 1.25 mm to about 2.25 mm, or about 1.5 mm to about 2.0 mm, e.g., about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, or about 3.0 mm.
In general, the movable component of the path length adjustment system can be made from any suitable material. Without wishing to be bound by any particular theory, the material should provide for wear resistance, flexibility, and low friction when installed in proximity to components of the print head against which it moves. Example materials for the movable component include, but are not limited to, polyphenylene sulfide (PPS), nylon, polyether ether ketone (PEEK), and metals, e.g., aluminum and steel. In some embodiments, the material for the movable component may include one or more additives to improve mechanical properties, e.g., wear resistance and surface friction, such as polytetrafluoroethylene (PTFE, i.e., TEFLON®), carbon, and graphite, among others. When a metal is used for the movable component, the metal may include a surface treatment to improve wear resistance, such as hardening (for steel) and anodizing (for aluminum).
As further illustrated in
As illustrated in
As further illustrated in
In some embodiments, the sliding component can be biased in an opposing direction to the filament feed direction. In some embodiments, the movable component, e.g., the sliding component, can be biased in a direction aligned to the filament feed direction. Without wishing to be bound by any particular theory, a pre-extrusion force is exerted onto the filament to aid in overcoming the drag forces experienced by the filament as it traverses or slides through printer components. For certain filament materials, e.g., filaments that buckle or stretch when external forces are applied, pre-extrusion forces may be insufficient to permit feeding of the print head with enough force to actuate the path length adjustment device. In these situations, applying a bias force to the sliding component in a direction opposing the filament feed direction or aligned with the filament feed direction can provide an assisting force to actuate the sliding component.
In another embodiment of a biased sliding component,
The function and advantages of these and other embodiments can be better understood from the following examples. These examples are intended to be illustrative in nature and are not considered to be in any way limiting the scope of the invention.
In this example, the tension of a filament being deposited at a fixed deposition rate was explored.
The print head of the 3D printer used to deposit the test filament included a path length adjustment device positioned on the print head between the pre-extrusion system and the feeding mechanism. The path length adjustment device included an optical sensor positioned towards the bottom of the movable component's motion range to detect the motion and position of the movable component. The movable component included a visual indicium that was detected by the optical sensor when the movable component was close to the bottom of the movable component's motion range. The feed mechanism was set to deposit a test filament at 500 mm/min. During printing, the filament being deposited caused the movable component to move to the bottom of the housing of the path length adjustment device, and the pre-extrusion system was configured to respond to this “bottoming out” by moving the movable component to extend the path length of the filament and add slack to the filament.
An example of the continuous path length adjustment of the filament being deposited at a fixed rate is illustrated in
As discussed herein, and in contrast to existing slack management devices with cumbersome and difficult to seal environments, the path length adjustment system used to produce the data illustrated in
The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,” “including,” “carrying,” “having,” “containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, i.e., to mean “including but not limited to.” Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. Only the transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to the claims. Use of ordinal terms such as “first,” “second,” “third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.
Having thus described several aspects of at least one embodiment, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Any feature described in any embodiment may be included in or substituted for any feature of any other embodiment. Such alterations, modifications, and improvements are intended to be part of this disclosure and are intended to be within the scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and/or configurations will depend on the specific application in which the disclosed methods and materials are used. Those skilled in the art should also recognize or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments disclosed.
This application claims priority to U.S. Patent Application No. 63/410,678, filed Sep. 28, 2022, the entire contents of which are incorporated herein by reference in their entirety.
Number | Date | Country | |
---|---|---|---|
63410678 | Sep 2022 | US |