Embodiments herein relate to a three-dimensional (3D) printing device.
3D printing is a form of additive manufacturing whereby industrial or consumer parts may be manufactured by adhering multiple layers of material on top of one another with a high precision computer driven applicator. The end result may be a physical 3D part which may be identical or closely similar to a 3D model generated by Computer Aided Design (CAD) software or other 3D design software.
In many cases the material used for 3D printing may be plastic. Typically, the plastic may be introduced to an extruder assembly. The extruder assembly may be the part of the 3D printing device that moves to extrude the 3D printing material in the shape of whatever layer of the 3D printed part it is currently making. Specifically, at the extruder assembly, a continuous strand of solid plastic build material may be melted, and the liquid plastic falls on top of the previous layer of the part being made as directed by movement of the extruder assembly.
Typically, the extruder assembly applies the plastic in a single plane. Once it has left the heating element of the extruder assembly, the liquid plastic build material rapidly cools back into a solid state and in so doing adheres to the other plastic around it, forming a continuous, solid plastic part.
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the spirit or scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.
Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order dependent.
The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments.
The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.
For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” means (A), (B), or (A and B). For the purposes of the description, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). For the purposes of the description, a phrase in the form “(A)B” means (B) or (AB) that is, A is an optional element.
The description may use the terms “embodiment” or “embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous.
3D printing devices may be generally thought of as machines that may construct parts up to a maximum size, termed a build volume. For 3D printing devices currently on the market, the build volume may still only be a fraction of the size of the 3D printing device itself. This size of the build volume may be limited because existing 3D printing devices may generally be described as large boxes that can build parts fitting into much smaller virtual boxes inside them. By contrast, embodiments of 3D printing devices described herein may have a build volume greater than the size of the printer itself, such as many times greater.
In embodiments, the angular movement may be achieved by rotating the orientation of a generally horizontal beam through actuation of a motor affixed to a gear. The radial r movement may be achieved by extending and contracting a telescoping arm driven by a single motor. The part of the telescoping arm to which the extruder assembly is attached may slide overtop of the rest of the telescoping arm, giving the extruder assembly access to radii smaller than that of the length of the most collapsed configuration of the telescoping arm. In other embodiments, the extruder assembly may be attached to a fixed point of the arm, and the arm may move laterally with respect to the column.
An embodiment of a 3D printing device 100 is shown in
The column 110 may have a substantially U-shaped cross-section formed by a hole or cut-out 140 (hereinafter hole 140) within the interior and the backside of the column 110. In other embodiments, the column 110 may have an alternative cross-sectional shape, for example circular or rectangular. In other embodiments, the hole 140 may have an alternative cross-sectional shape, while in other embodiments the hole 140 may not be present in some or all of the column 110. Additionally, in other embodiments, the 3D printing device 100 may include multiple columns, and more than one column may be attached to a climber 115. For example, in some embodiments the climber 115 may be suspended between one or more columns.
A beam 120 may be coupled with the climber 115. As shown in
An I-beam 125 may be positioned at least partially within the beam 120. In some embodiments, and as will be discussed in greater detail below, the I-beam 125 may be configured to extend from the beam 120 to extend the radius of the 3D printing device 100. Additionally, as noted below, in some embodiments the I-beam 125 may have an alternative cross-sectional shape. The term “I-beam” is used herein for convenience, but should not be construed as specifically limiting the cross-sectional structure of the beam.
An extruder assembly 130 may be coupled with the beam 120. Specifically, the extruder assembly 130 may be configured to move laterally with respect to the beam 120. In other words, the extruder assembly 130 may be configured to move laterally either closer to or farther from the column 110. If the I-beam 125 is extended from the beam 120, then the extruder assembly 130 may be further configured to move along the extended I-beam 125 to move even further from the column 110. The extruder assembly 130 may include one or more of a gear, a motor, a heating element, circuitry, a nozzle, or other elements. As shown in
In one embodiment, an extension of the climber 215 may be positioned within the hole 240 of the column 210. Within this extension, a pinion gear assembly 255 of the climber 215 may be mated to two identical inward facing rack gears 250 coupled with or machined into the column 210. For example, the rack gears 250 may be coupled with the front and back faces of the hole 240. In other embodiments, a single rack gear or more than two rack gears may be mated with a single pinion gear or more than two pinion gears. In some embodiments, a drive belt may be used in lieu of or in conjunction with a gear or gears.
The climber 215 may move up or down the column 210 by operation of a motor 245, which may be affixed to the climber 215. The motor 245 may turn one or both of the gears of the pinion gear assembly 255, which in turn drives the pinion gear assembly 255 along the rack gears 250. In embodiments where the rack gears 250 are on opposite faces of the hole 240, the gears of the pinion gear assembly 255 may move in opposite directions from one another. In embodiments where the gears of the pinion gear assembly 255 are linear, that is connecting with a single rack gear 250, the gears may move in the same direction as one another. In other embodiments, other gear assemblies may be used. For example, gear assemblies using methods other than a rack and pinion (such as a rotating threaded screw, a belt system or others) may be used to cause climber 215 to move vertically.
In embodiments, the extruder assembly 230 may be configured to rotate angularly around angle θ through angular rotation of the beam 220 with respect to the column 210. Specifically, the beam 220 may angularly rotate with its axis of rotation intersecting with the climber 215 as shown in
As described above, one or both of I-beam 225 and extruder assembly 230 may move radially along the axis of the beam 220. In one embodiment, a motor 270, which may be affixed to the I-beam 225 may rotate a gear 275. The gear 275 may, in turn, rotate axle 280 and its attached gear, which in some cases may be a pinion gear. The pinion gear coupled with the axle 280 may move along a rack gear coupled with an interior face of the beam 220. This movement of the pinion gear along the rack gear may cause the I-beam 225 to move inward or outward with respect to the beam 220. Although some embodiments use an I-beam, the use of the term “I-beam” with regard to the I-beam 225 is only descriptive of one embodiment, and the I-beam 225 may have other cross-sectional shapes or structures in other embodiments.
The axle 280 may also drive a belt 285, which may be affixed to the extruder assembly 230. As the belt 285 moves, the extruder assembly 230 may move horizontally along the outside of one or both of the beam 220 and/or I-beam 225. In some embodiments, the axle 280 may be configured to drive the belt 285 while being disengaged from the pinion gear coupled with the axle 280. Additionally or alternatively, the axle 280 may be operable to drive the pinion gear coupled with the axle 280 while it is disengaged from the belt 285. In some embodiments, the axle 280 may simultaneously drive both the belt 285 and the pinion gear coupled with the axle 280.
As shown in
As described above, the beam 420 may be configured to angularly rotate around pivot point 401 with respect to the column 410 and climber 415.
An extruder assembly 530 may be affixed to the beam 520. As shown in
The column 510 may angularly rotate relative to the platform 502 based at least in part on the operation of a motor such as motor 517. The motor 517 may be affixed to the base of the column 510, and may be operable to rotate a pinion gear such as gear 522 along an arced rack gear recessed into the top of the platform 502. Rotation of the gear 522 in one direction may cause the column 510, and the attached assembly components described above, to angularly rotate in the clockwise direction with respect to the platform 502 and/or base 505. Rotation of the gear 522 in another direction may likewise cause the column 510 and the attached assembly components described above to angularly rotate in the counterclockwise direction. Other embodiments may include additional motors. Alternatively, the motor 517 may be attached to a different area of the 3D printing device 500, or even separate from the 3D printing device 500 but attached to the column 510, for example by a belt drive.
In one embodiment, the climber 515 may move vertically due to operation of a motor such as motor 557. The motor 557 may be affixed to the base of the column 510, and may be configured to rotate a gear train such as gear train 562, which in turn may cause a lead screw such as lead screw 527 to rotate. The climber 515 may be coupled with the lead screw 527 such that rotation of the lead screw 527 in one direction causes the climber 515 to move upward, and rotation of the lead screw 527 in another direction causes the climber 515 to move downward. In other embodiments the motor 557 may be coupled directly with the lead screw 527. In still other embodiments the climber 515 may be configured to move vertically according to or based on other configurations such as the rack and pinion assembly described above with respect to the 3D printing devices 100 and 200 or by another method such as a drive belt.
Beam 520 may move horizontally with respect to the base 505 and column 510 through operation of a motor such as motor 532. Motor 532 may be affixed to a top portion of the climber 515, and configured to rotate a pinion gear such as gear 537 along a rack gear affixed along a face such as an inside face of the beam 520. Rotation of the gear 537 in one direction may cause the beam 520 to move to the right (when the 3D printing device 500 is viewed from one side), and rotation of the gear 537 in another direction may cause the beam 520 to move to the left (when the 3D printing device 500 is viewed from the same side). This movement may be viewed as extension or contraction of the beam 520 with respect to the column 510. In other embodiments, the motor 532 may be placed at a different location with respect to the beam 520, climber 515, and/or column 510.
An extruder assembly 530 may be similar to the extruder assembly described above such as, for example, extruder assembly 130, and coupled with the beam 520 as described above. The extruder assembly 530 may be configured to add material to a 3D printed part. Specifically, a continuous strand of build material 552 may flexibly extend from the material cartridge 512 to the top of the extruder assembly 530. To apply the build material 552 to the 3D printed part, one or more components of the extruder assembly 530 such as the extruding nozzle 506, or a separate element of the extruder assembly 530 which is coupled with the extruding nozzle 506 may be heated to a temperature sufficient to melt the build material 552. For example, the extruding nozzle 506 may be heated to a temperature of at least 90 degrees Fahrenheit (32.2 degrees Celsius). Then, when the extruder assembly 530 is in the appropriate location to begin adding the build material 552, the motor 542 may rotate a gear or gear train 547 to feed build material 552 into the top of the extruding nozzle 506 (or alternatively, into the heating element). This process may continue while the 3D printing device 500 changes its orientation via radial, angular or vertical rotations and movements described above with respect to 3D printing devices 100, 200, 300, or 400 to move the extruder assembly 530 along a desired path in 3D space. As noted above, the material cartridge 512 may be attached at a different point with regard to the column 510, or the extruding assembly 530. For example, the material cartridge 512 may be entirely separate from the 3D printing device 500, but still situated such that build material 552 may extend from the material cartridge 512 to the extruding assembly 530. In some embodiments, the extruder assembly may be separated into one or more parts (not shown in
In embodiments, all three axes of motion (vertical ‘z’, radial ‘r’, and angular ‘theta’) of the 3D printing devices 100, 200, 300, 400, and 500 may move independently of each other, allowing the point at which 3D printed material leaves the extruding assembly to move within a very large 3-dimensional volume when compared to the size of 3D printing device 100.
Although three 3D printing devices 600A, 600B, and 600C are depicted in
As noted above, the input design file may include Cartesian coordinates, and so the output extruder paths may then be converted into a series of polar coordinate positions at 820 using one or several elements of computer software. Finally, these polar coordinate positions may be converted into inputs to motors to generate radial movement at 825, angular movement at 830, and/or vertical movement at 835 of an embodiment of a 3D printing device. A signal may also be generated using one or several elements of computer software for movement of the material cartridge 512 or one or more elements of the extruder assembly 530 to feed build material 552 into the extruder assembly 530, or extrude build material 552 from the extruding nozzle 506 to apply material to a 3D part being constructed at 840.
The movements generated at 825, 830, 835, and/or 840 in concert may cause the extruding assembly of a 3D printing device to follow the extruder path and apply material and thereby create the desired shape. As described above, in some embodiments, the conversion at 820 may be unnecessary because the design file may already contain the extruder path in polar coordinates. Some or all of the computational processing and/or electrical signal generation described herein may occur in an electrical circuit or on a circuit board such as the circuit board 507 described above with respect to
Although certain embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope. Those with skill in the art will readily appreciate that embodiments may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments be limited only by the claims and the equivalents thereof.
The present application claims priority to U.S. Provisional Patent Application No. 61/692,965, filed Aug. 24, 2012, entitled “3D Printer,” and No. 61/728,640, filed Nov. 20, 2012, entitled “3D Printer,” the entire disclosures of which are hereby incorporated by reference in their entirety.
Number | Date | Country | |
---|---|---|---|
61728640 | Nov 2012 | US | |
61692965 | Aug 2012 | US |