EP4323193A1 - Dreidimensionaler drucker - Google Patents

Dreidimensionaler drucker

Info

Publication number
EP4323193A1
EP4323193A1 EP22796623.1A EP22796623A EP4323193A1 EP 4323193 A1 EP4323193 A1 EP 4323193A1 EP 22796623 A EP22796623 A EP 22796623A EP 4323193 A1 EP4323193 A1 EP 4323193A1
Authority
EP
European Patent Office
Prior art keywords
axis
nozzle
along
print head
dimensional printer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22796623.1A
Other languages
English (en)
French (fr)
Inventor
Yasushi Mizuno
Alexander STOCKTON
Iris Gisey Euan Waldestrand
Scott Matthews
Jorge Arturo Mijares Tobias
Matthew SKOLAUT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Essentium Ipco LLC
Original Assignee
Essentium Ipco LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US17/241,843 external-priority patent/US11642845B2/en
Application filed by Essentium Ipco LLC filed Critical Essentium Ipco LLC
Publication of EP4323193A1 publication Critical patent/EP4323193A1/de
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

Definitions

  • the present disclosure relates to three-dimensional printers that manufacture additive printed parts. More particularly, in aspects, the present disclosure relates to three-dimensional printer components that facilitate the operation of a three-dimensional printer, and in particular aspects three-dimensional printers including more than one print head.
  • Three-dimensional printers are utilized by many industries to quickly produce parts by additive deposition of material.
  • Three-dimensional printers generally include a print head that heats a filament comprising a polymer and deposits the molten filament onto a print bed in progressive layers to form the part.
  • various challenges arise, particularly in incorporating multiple independent print heads in a printer.
  • Some three-dimensional printers utilize two print heads that may be utilized cooperatively to produce a single part or individually to produce two parts.
  • the two print heads and the bed support are often open to the outside air.
  • the outside air is significantly cooler than the molten filament and is uncontrolled.
  • the cooling rate of the filament is generally fast and uncontrolled, leading to inconsistencies and imperfections in the structure and appearance of the parts.
  • attempts to control the cooling rate of the molten filament by placing the print bed and the print heads in a heated chamber have led to degradation of the heat-sensitive electronics that control the print heads.
  • excess material develops on the nozzle of most three- dimensional printers.
  • the most common cause for the development of excess material on the nozzle is when a print head is paused during a printing operation or stopped after completion of a printing operation and is particularly prevalent when more than one print head is present.
  • the molten filament seeps from the tip of the nozzle due to remaining pressure within the nozzle, commonly referred to in the art as “drool.”
  • This drool can become hardened on the tip, making the flow of molten filament through the nozzle difficult.
  • liquid drool disposed on the tip of the nozzle may detach during a subsequent print operation and produce a flaw in the printed part. The removal of the excess material from the tip of the nozzle is important to ensure the quality of the printed part.
  • the location of the print head must be precisely positioned relative to the print bed.
  • tolerances must be designed into the components of the print head and the print bed in order to facilitate the movements needed to operate the printer. Because of the tolerances, the locations of the print head and the print bed often vary after use from their original locations. As a result, the print head and the print bed are in a different location than what the control system (which operates the three-dimensional printer) believes they are in, which can cause part irregularities and defects.
  • location variations can cause the print head and the print bed to collide and damage one another. Again, this is particularly prevalent where more than one print head is utilized.
  • Some three-dimensional printers calibrate the locations of the print head and the print bed by calibrating the stored location in the control system with the actual location of the print head and the print bed. Often, the three-dimensional printer performs a test print in which the print head deposits material on the print bed. The product produced on the print bed is analyzed by a technician. The technician uses their skill and experience to calibrate the control system to correct the location variations. Although useful, this method is dependent upon the skill of the technician and is susceptible to human error. Furthermore, this method of calibration takes a great amount of time to perform, which results in longer downtime of the three-dimensional printer and reduced throughput of the printed parts.
  • a three-dimensional printer for manufacturing additive printed parts comprises a housing defining a cavity and first and second fixed rails extending parallel to one another along a first axis and mounted to the housing.
  • the three- dimensional printer further comprises first and second movable rails extending parallel to one another along a second axis, orthogonal to the first axis, with the first and second movable rails coupled to both of the first and second fixed rails and arranged to move independent of other another along the first axis on the first and second fixed rails.
  • the three-dimensional printer further comprises a first print head coupled to and movable along the second axis on the first movable rail.
  • the three-dimensional printer further comprises a second print head coupled to and movable along the second axis on the second movable rail, independent of the first print head.
  • the three-dimensional printer further comprises first, second, and third dividers extending between the first and second fixed rails and collectively separating the cavity to partially define a process chamber and an instrument chamber.
  • the first divider is mounted to both the housing and the first movable rail and is arranged to expand and contract with the movement of the first movable rail along the first axis.
  • the second divider is mounted to both of the housing and the second movable rail and is arranged to expand and contract with the movement of the second movable rail along the first axis.
  • each of the first, second, and third dividers comprise a plurality of alternating upper pleats and lower pleats that are configured to open when expanded and close when contracted.
  • the upper pleats and the lower pleats extend along the second axis to facilitate expansion and contraction of the first, second, and third dividers along the first axis.
  • each of the first, second, and third dividers have a compression ratio at least 10:1.
  • each of the first, second, and third dividers comprise a plurality of strips that are sequentially disposed such that each strip partially defines one of the upper pleats and one of the lower pleats.
  • each of the strips comprise a body extending to opposing upper contact walls and lower contact walls, with the upper contact walls of adjacent strips joined to one another at the upper pleat and with the lower contact walls of adjacent strips joined to one another at the lower pleat.
  • the adjacent upper contact walls and adjacent lower contact walls are joined together by a mechanical fastener.
  • the mechanical fastener is further defined as thread, with adjacent strips joined to another by sewing.
  • the three-dimensional printer further comprises a plurality of support members individually disposed in the lower pleats to retain the first, second, and third dividers in a substantially planar configuration along the first and second axes.
  • each support member defines a plurality of holes extending therethrough, with adjacent strips joined together through the holes to couple together the strips and the supports.
  • each of the strips comprise a lower contact wall, with the support members individually disposed between adjacent strips and mounted to the respective lower contact walls.
  • the support members and the lower contact walls each have a cross-sectional area, with the cross-sectional area of each support member greater than the cross-sectional area of each lower contact wall to resist bending.
  • each support member has a thickness of 0.1mm - 0.3mm.
  • the support members are comprised of spring steel.
  • first, second, and third dividers are comprised of an insulative material to reduce thermal transmission between the process and instrument chambers.
  • the insulative material is further defined as a carbon-aramide fabric having an aluminized coating facing the process chamber.
  • each of the first and second movable rails comprise a pair of tracks extending parallel one another with the print heads disposed between and movably coupled to the tracks.
  • each of the first and second movable rails comprise a pair of rail dividers disposed between the pair of tracks on opposing sides of the print head, with the pair of rail dividers arranged to expand and contract with the movement of the print head along the movable rail.
  • the three-dimensional printer further comprises each of the rail dividers comprise a plurality of alternating upper pleats and lower pleats that are configured to open when expanded and close when contracted, with the upper pleats and the lower pleats of the rail dividers orthogonal to the upper pleats and the lower pleats of the first, second, and third dividers.
  • a printed circuit board is disposed in the instrument chamber and operably coupled to at least one of the first and second print heads.
  • a three-dimensional printer for manufacturing additive printed parts comprises a housing defining a cavity and at least one print head comprising a nozzle for ejecting material to form the additive printed parts, with the print head movable along a first axis and a second axis, orthogonal to the first axis.
  • the three- dimensional printer further comprises at least one wiper assembly for cleaning the excess material off the nozzle.
  • the wiper assembly is disposed in the cavity and is mounted to the housing.
  • the wiper assembly comprises a collection bin and a chute having a first end coupled to the collection bin and a second end spaced from the collection bin.
  • the wiper assembly further comprises a blade having a planar configuration and disposed at the second end of the chute, with the blade extending upwardly along a third axis, orthogonal to both the first and second axes, and arranged to contact a tip of the nozzle and bend as the print head passes over the blade and forcefully remove the material as the nozzle moves past the blade and elastically returns to the planar configuration.
  • the wiper assembly further comprises a brush disposed at the second end of the chute. The brush extends upwardly along the third axis and is arranged to contact the tip of the nozzle and wipe off remaining material as the print head passes over the brush, after the blade.
  • a three-dimensional printer for manufacturing additive printed parts comprises at least one print head comprising a nozzle for ejecting material to form the additive printed parts.
  • the print head is movable along a first axis and a second axis, orthogonal to the first axis.
  • the three-dimensional printer further comprises a build table disposed below the print head and movable towards and away from the print head along a third axis, orthogonal to both the first and second axes.
  • the build table is configured to receive the material ejected from the nozzle forming the additive printed parts.
  • the three-dimensional printer further comprises a calibration switch mounted to the build table.
  • the calibration switch comprises a base, a plunger supported by the base and movable along the third axis, and a sensor arranged to detect movement of the plunger along the third axis.
  • the three-dimensional printer further comprises a control system in communication with the print head, the build table, and the calibration switch.
  • the control system is arranged to perform a calibration sequence in which the print head is arranged to move along the first and second axes over the calibration switch, the build table is arranged to move towards and away from the print head as the print head moves over the calibration switch, the sensor is arranged to send a signal to the control system when the nozzle contacts and moves the plunger, and the control system is arranged to determine a location of the nozzle along the first, second, and third axes in relation to the build table based upon the signal from the sensor.
  • the calibration sequence is further defined as the print head being arranged to move along the first and second axes in a calibration pattern over the calibration switch, the build table being arranged to cyclically move towards and away from the print head as the print head moves in the calibration pattern over the calibration switch, the sensor being arranged to send a signal to the control system when the nozzle contacts and moves the plunger as the print head moves in the calibration pattern, and the control system being arranged to determine a location of the nozzle along the first, second, and third axes in relation to the build table based upon the signal from the sensor.
  • the calibration pattern of the print head is a cross configuration having a single pass across the calibration switch along the first axis and a single pass across the calibration switch along the second axis.
  • the plunger has a contact surface arranged to engage the nozzle, with the contact surface having a planar configuration.
  • the calibration pattern of the print head is a switch-back configuration having a plurality of reversing passes across the calibration switch along one of the first and second axes that are progressively spaced from one another along the other one of the first and second axes.
  • the plunger has a contact surface arranged to engage the nozzle, with the contact surface having an arcuate configuration.
  • the nozzle is arranged to move along the third axis and print head further comprises an anti-crash sensor arranged to detect movement of the nozzle along the third axis for preventing damage to the nozzle when contacting an immovable surface.
  • each of the plunger and the nozzle are biased to resist movement along the third axis, with the bias of the nozzle being greater than the bias of the plunger such that the sensor of the calibration switch is arranged to send a signal to the control system prior to the anti-crash sensor.
  • the calibration sequence further comprises the build table being arranged to move towards the print head, the sensor of the calibration switch being arranged to send a signal to the control system when the nozzle contacts and moves the plunger, the build table arranged to continue movement towards the print head, the anti-crash sensor of the nozzle arranged to send a nozzle trigger signal to the control system, and the control system arranged to determine a trigger-travel distance of the nozzle along the third axis based upon the movement of the print head between the signal from the calibration switch and the signal from the anti-crash sensor.
  • the nozzle comprises a heater for warming the material and wherein the calibration sequence determines the trigger-travel distance of the nozzle when warmed by the heater and determines the percent elongation of the nozzle.
  • the at least one print head is further defined as a first print head and a second print head independently movable along the first and second axes and each comprising the nozzle, with each of the first and second print heads arranged to move over the calibration switch to determine the locations of the nozzles along the first, second, and third axes in relation to the build table based upon the signal from the sensor.
  • a method of calibrating a three-dimensional printer comprises at least one print head, a build table, a calibration switch mounted to the build table, and a control system in communication with the print head, the build table, and the calibration switch.
  • the method comprises moving the print head, comprising a nozzle, along a first axis and a second axis, orthogonal to the first axis, over the calibration switch comprising a base, a plunger supported by the base and movable along the third axis, and a sensor arranged to detect movement of the plunger along the third axis.
  • the method further comprises moving the build table towards the print head as the print head moves over the calibration switch and moving the plunger of the calibration switch with the nozzle of the print head.
  • the method further comprises sensing the movement of the plunger with the sensor of the calibration switch, sending a signal from the sensor to the control system, and determining a location of the nozzle along the first, second, and third axes in relation to the build table based upon the signal from the sensor.
  • moving the print head is further defined as moving the print head in a calibration pattern over the calibration switch.
  • Moving the build table towards the print head is further defined as moving the build table cyclically towards and away from the print head as the print head moves in the calibration pattern over the calibration switch.
  • moving the plunger of the calibration switch with the nozzle of the print head is further defined as repeatedly moving the plunger of the calibration switch toward and away from the base along the third axis with the nozzle of the print head.
  • Sensing the movement of the plunger with the sensor of the calibration switch is further defined as sensing each movement of the plunger toward the base with the sensor of the calibration switch.
  • Sending a signal from the sensor to the control system is further defined as sending a signal from the sensor to the control system each time the nozzle contacts and moves the plunger toward the base.
  • Determining a location of the nozzle along the first, second, and third axes in relation to the build table based upon the signal from the sensor is further defined as determining a location of the nozzle along the first, second, and third axes in relation to the build table with an algorithm based upon the signals from the sensor.
  • the plunger has a contact surface arranged to engage the nozzle, with the contact surface having a planar configuration.
  • Moving the print head in a calibration pattern over the calibration switch is further defined as moving the print head in a cross configuration having a single pass across the calibration switch along the first axis and a single pass across the calibration switch along the second axis.
  • determining a location of the nozzle along the first, second, and third axes in relation to the build table with an algorithm based upon the signals from the sensor is further defined as determining a location of the nozzle along the first, second, and third axes in relation to the build table by finding a midpoint of first axis values from the signals generated along the single pass on the first axis to generate a zero first axis location of the nozzle, finding a midpoint of second axis values from the signals generated along the single pass on the second axis to generate a zero second axis location of the nozzle, and finding an average of third axis values from the signals generated along both of the passes on the first and second axes to generate a zero third axis location of the nozzle.
  • the plunger has a contact surface arranged to engage the nozzle, with the contact surface having an arcuate configuration.
  • Moving the print head in a calibration pattern over the calibration switch is further defined as moving the print head in a switch-back configuration having a plurality of reversing passes across the calibration switch along one of the first and second axes that are progressively spaced from one another along the other one of the first and second axes.
  • the nozzle is arranged to move along the third axis and print head further comprises an anti-crash sensor arranged to detect movement of the nozzle along the third axis, with each of the plunger and the nozzle biased to resist movement along the third axis, and with the bias of the nozzle being greater than the bias of the plunger such that the sensor of the calibration switch is arranged to send a signal to the control system prior to the anti-crash sensor.
  • the method further comprises continuing to move the build table towards the print head after completely moving the plunger of the calibration switch, moving the nozzle along the third axis, and sensing the movement of the nozzle with the anti-crash sensor.
  • the method further comprises sending a nozzle trigger signal from the anti-crash sensor to the control system and determining a trigger-travel distance of the nozzle along the third axis based upon the movement of the print head between the signal from the calibration switch and the nozzle trigger signal from the anti-crash sensor.
  • the nozzle comprises a heater for warming material to form an additive printed part.
  • the method further comprises warming the nozzle with the heater, moving the build table towards the print head, and moving the plunger of the calibration switch with the nozzle of the print head.
  • the method further comprises continuing to move the build table towards the print head after completely moving the plunger of the calibration switch, moving the nozzle along the third axis, sensing the movement of the nozzle with the anti-crash sensor, sending a heated nozzle trigger signal from the anti-crash sensor to the control system, and determining a heated trigger-travel distance of the nozzle along the third axis based upon the movement of the print head between the signal from the calibration switch and the heated nozzle trigger signal from the anti-crash sensor.
  • the method further comprises comparing the trigger-travel distance with the heated trigger- travel distance to determine a percent elongation of the nozzle along the third axis.
  • the print head is further defined as a first print head and a second print head independently movable along the first and second axes and each comprising the nozzle.
  • Moving the print head over the calibration switch is further defined as moving one of the first and second print heads over the calibration switch.
  • FIG. 1 is a perspective view of a three-dimensional printer.
  • FIG. 2 is a perspective view of a portion of the three- dimensional printer of FIG. 1 , showing first and second print heads, first and second fixed rails, first and second movable rails, and first, second, and third dividers of the three-dimensional printer, as seen from above the first fixed rail.
  • FIG. 3 is a perspective view of the portion of the three- dimensional printer shown in FIG. 2, as seen from above the second fixed rail.
  • FIG. 4 is a perspective view of the portion of the three- dimensional printer shown in FIG. 2, as seen from below the first fixed rail.
  • FIG. 5 is an elevational view of the portion of the three- dimensional printer shown in FIG. 2.
  • FIG. 6 is an elevational view of the portion of the three- dimensional printer shown in FIG. 2, with the first movable rail and the first print head moved from their positions in FIG 5.
  • FIG. 7 is a perspective view of the first divider of FIG. 2, shown in an expanded configuration.
  • FIG. 8 is a perspective view of the first divider of FIG. 2, shown in a contracted configuration.
  • FIG. 9 is a cross-sectional view of a portion of the first divider, taken along line 9-9 in FIG. 7.
  • FIG. 10 is a perspective view of a portion of first divider FIG. 2, showing support members of the first divider.
  • FIG. 11 is a perspective view of a first wiper assembly comprising a blade, a brush, a chute, and a collection bin.
  • FIG. 12 is a perspective view of the first wiper assembly of FIG. 11 , showing the blade and the brush.
  • FIG. 13 is a side elevational view of the first wiper assembly of FIG. 11 , showing the blade and the brush and a nozzle of the first print head.
  • FIG. 14 is a top elevational view showing the first wiper assembly of FIG. 11 and a second wiper assembly disposed within the housing.
  • FIG. 15 is a perspective view of another example of the first wiper assembly, showing the blade and the brush askew.
  • FIG. 16 is a perspective view of another example of the first wiper assembly, showing the blade and the brush askew.
  • FIG. 17 is a perspective view of the first wiper assembly of FIG. 16.
  • FIG. 18 is a perspective view of another example of the first wiper assembly, showing the blade and the brush askew.
  • FIG. 19 is a perspective view of another example of the first wiper assembly, showing the blade and the brush askew.
  • FIG. 20 is a perspective view of a calibration switch, showing a base, a sensor, and a plunger having a planar configuration.
  • FIG. 21 A is a side elevational view of the calibration switch shown in FIG. 2 and a nozzle of the first print head disposed above the base of the calibration switch in a calibration sequence.
  • FIG. 21 B is a side elevational view of the calibration switch shown in FIG. 2 and the nozzle of the first print head contacting the base of the calibration switch in the calibration sequence.
  • FIG. 21 C is a side elevational view of the calibration switch shown in FIG. 2 and the nozzle of the first print head disposed above the plunger of the calibration switch in the calibration sequence.
  • FIG. 21 D is a side elevational view of the calibration switch shown in FIG. 2 and the nozzle of the first print head contacting the plunger of the calibration switch in the calibration sequence.
  • FIG. 22 is a schematic view of a calibration pattern of the nozzle of the first print head across the calibration switch shown in FIG. 2, the calibration pattern having a cross configuration.
  • FIG. 23 is a perspective view of a calibration switch, showing a base, a sensor, and a plunger having an arcuate configuration.
  • FIG. 24 is a perspective view of the calibration switch shown in FIG. 23 and the nozzle of the first print head contacting the plunger having the arcuate configuration.
  • FIG. 25 is a schematic view of a calibration pattern of the nozzle of the first print head across the calibration switch of FIG. 23, the calibration pattern having a switch-back configuration.
  • FIG. 26A is a side elevational view of the calibration switch shown in FIG. 20 and the nozzle of the first print head contacting the plunger of the calibration switch in the calibration sequence and showing an anti-crash sensor.
  • FIG. 26B is a side elevational view of the calibration switch and the nozzle shown in FIG. 26A, with the nozzle contacting the plunger of the calibration switch in the calibration sequence and with the nozzle moved upward and detected by the anti-crash sensor.
  • FIG. 26C is a side elevational view of the calibration switch and the nozzle shown in FIG. 26A, with the nozzle contacting the plunger of the calibration switch in the calibration sequence and with the nozzle moved upward and detected by the anti-crash sensor and showing a heater that has heated and elongate the nozzle through thermal expansion.
  • a three-dimensional printer for manufacturing additive printed parts is shown generally at 20.
  • the three- dimensional printer 20 comprises a housing 22 defining a cavity 24, within which components of the three-dimensional printer 20 are supported.
  • the three-dimensional printer 20 comprises first and second fixed rails 26, 28 extending parallel to one another along a first axis A1 and mounted to the housing 22.
  • the three-dimensional printer 20 further comprises first and second movable rails 30, 32 extending parallel to one another along a second axis A2, orthogonal to the first axis A1.
  • the first and second movable rails 30, 32 are coupled to both of the first and second fixed rails 26, 28 and are arranged to move independent of other another along the first axis A1 on the first and second fixed rails 26, 28.
  • the first and second fixed rails 26, 28 may extend along a pair of opposing walls of the housing 22.
  • the pair of opposing walls are the front and rear walls of the housing 22.
  • the first and second fixed rails 26, 28 may be disposed anywhere within the cavity 24 of the housing 22.
  • the three-dimensional printer 20 further comprises a first print head 34 coupled to and movable along the second axis A2 on the first movable rail 30 and a second print head 36 coupled to and movable along the second axis A2 on the second movable rail 32, independent of the first print head 34.
  • the first axis A1 is associated with what is commonly referred to in the art as the x axis and the second axis A2 is associated with what is commonly referred to in the art as the y axis.
  • the x and y axes (along with a z axis that extends orthogonal to both the x axis and the y axis) establish a three-dimensional coordinate system that is used by the three- dimensional printer 20 to spatially locate the first and second print heads 34, 36, as well as the additive printed parts that will be produced by the first and second print heads 34, 36.
  • the first and second axes A1 , A2 are associated with the x and y axes, respectively, the opposite may be true (i.e. , the first axis A1 may be associated with the y axis and the second axis A2 may be associated with the x axis).
  • first and second axes A1 , A2 may not directly correspond to any of the x, y, and z axes. Said differently, the first and second axes A1 , A2 may be angularly and translationally misaligned from the x, y, and z axes.
  • the three-dimensional printer 20 may further comprise a first filament cartridge 38 having a first filament and a second filament cartridge 40 having a second filament, as shown in Figure 1.
  • the first filament extends from the first filament cartridge 38 to the first print head 34 and the second filament extends from the second filament cartridge 40 to the second print head 36.
  • the first and second print heads 34, 36 are moveable two-dimensionally in a horizontal plane along the first axis A1 and the second axis A2 within the housing 22. Moreover, the first and second print heads 34, 36 are movable independent of one another along the first and second axes A1 , A2.
  • Each of the first and second print heads 34, 36 comprise an extruder 42, 44 (as shown in Figures 2 and 3) and a nozzle 46, 48 (as shown in Figure 4).
  • the extruder 42, 44 includes a print head feed motor and is adapted to pull the filament into the print head 34, 36. The extruder 42, 44 then feeds the filament to the nozzle 46, 48.
  • the nozzle 46, 48 includes a heater (see, e.g., 230 in FIG. 26C) that melts the filament as it enters the nozzle 46, 48.
  • the nozzle 46, 48 also includes a tip 50, 52 adapted to feed molten filament material out of the nozzle 46, 48 to be deposited when an additive printed part is being created. Continual feeding of the filament into the nozzle 46, 48 by the extruder 42, 44 pushes the molten filament material through the tip 50, 52 of the nozzle 46, 48 to be deposited.
  • a build table 54 is supported below the print head 34, 36 and is vertically movable up and down along a third axis A3.
  • the third axis A3 is associated with the z axis, referred to above.
  • the third axis A3 may correspond to the x or y axes or may not be associated with any one of the x, y, and z axes.
  • the build table 54 also includes a print bed 56.
  • the print bed 56 provides a surface onto which one or more additive printed parts are created within the three-dimensional printer 20.
  • the build table 54 starts out positioned high within the three-dimensional printer 20 near the first and second print heads 34, 36.
  • the first and second print heads 34, 36 are configured to move back and forth two dimensionally along the first and second axes A1 , A2 and deposit the molten filament material onto the print bed 56, creating a two- dimensional shape on the print bed 56. Once fed from the tip 50, 52 of the nozzle 46, 48 the molten filament material quickly hardens sufficiently to hold shape.
  • the build table 54 gradually moves along the third axis A3 away from the print head 34, 36 as successive layers of molten filament material are deposited on previously deposited layers of now hardened filament material.
  • the first and second print heads 34, 36 continue to add successive layers onto the forming additive printed part until a final three-dimensional shape is formed.
  • the first and second filaments are polymers; however, any suitable material capable of being melted and deposited to form the additive printed parts may be utilized.
  • the first and second print heads 34, 36 are capable of moving completely independent of one another along the first and second axes A1 , A2. More specifically, the first and second print heads 34, 36 are capable of moving independent of one another along the first axis A1 through the independent movement of the first and second movable rails 30, 32 along the first and second fixed rails 26, 28, as shown between Figures 5 and 6. Furthermore, the first and second print heads 34, 36 are capable of moving independent of one another along the second axis A2 through their own independent movement along the first and second movable rails 30, 32, respectively. The independent movement of the first and second print heads 34, 36 facilitate several functions of the three-dimensional printer 20. The first and second print heads 34, 36 may each individually produce an additive printed part.
  • first and second print heads 34, 36 may collaboratively form a single additive printed part.
  • first and second filaments of the first and second print heads 34, 36 may be different (e.g., different compositions, different colors, etc.)
  • the first and second print heads 34, 36 may be synchronized to deposit the molten first and second filaments, respectively, to form one additive printed part.
  • the description below refers to the print head 34, 36 in the singular form. It is to be appreciated that, unless stated otherwise, the following description is applicable to either of the first and second print heads 34, 36.
  • the three-dimensional printer 20 further comprises first, second, and third dividers 58A-C extending between the first and second fixed rails 26, 28 and collectively separating the cavity 24 to partially define a process chamber 60 and an instrument chamber 62, as shown in Figure 1.
  • the first, second, and third dividers 58A-C are substantially planar, with the process chamber 60 disposed below the dividers 58A-C and the instrument chamber 62 is disposed above the dividers 58A-C.
  • the build table 54 and the nozzles 46, 48 of the first and second print heads 34, 36 are disposed in the process chamber 60.
  • the process chamber 60 is a region in which the additive printed part(s) are formed.
  • the instrument chamber 62 houses the extruders 42, 44 of the first and second print heads 34, 36, as well as other components that control the operation of the first and second print heads 34, 36. Therefore, the dividers 58A-C serve as a barrier between the chambers that protects the relatively delicate components disposed in the instrument chamber 62. Not only do the dividers 58A-C provide a physical barrier between the chambers, the dividers 58A-C also provide a thermal barrier, which will be described in greater detail below.
  • Each of the first, second, and third dividers 58A-C extend across the cavity 24 along the second axis A2 and into proximity with the first and second fixed rails 26, 28.
  • the dividers 58A-C may abut or overlap the first and second fixed rails 26, 28.
  • the dividers 58A-C may also be spaced from the first and second fixed rails 26, 28 to allow for movement of the dividers 58A- C relative to the first and second fixed rails 26, 28, while still be substantially covering the space between the first and second fixed rails 26, 28.
  • the first divider is mounted to both the housing 22 and the first movable rail 30 and is arranged to expand and contract with the movement of the first movable rail 30 along the first axis A1.
  • the second divider is mounted to both of the housing 22 and the second movable rail 32 and is arranged to expand and contract with the movement of the second movable rail 32 along the first axis A1.
  • first and second dividers 58A, 58B are mounted to opposing sides of the housing 22 (which in this example are the left and right sides of the housing 22) and extend inwardly along the first axis A1 , with the first and second dividers 58A, 58B mounted to the closest proximate movable rail (which is the first movable rail 30 for the first divider and the second movable rail 32 for the second divider).
  • the third divider is mounted to both of the first and second movable rails 30, 32 and is arranged to expand and contract with the movement of one or both of the first and second movable rails 30, 32 along the first axis A1.
  • the first, second, and third dividers 58A-C collectively form a barrier that extends across the along cavity 24 along the first axis A1. More specifically, the first and second dividers 58A, 58B form barriers across the outer regions of the cavity 24 between the movable rails 30, 32 the opposing walls of the housing 22, while the third divider forms a barrier between the first and second movable rails 30, 32.
  • the arrangement of the first, second, and third barrier to expand and contract with the movement of the first and second movable rails 30, 32 ensures that the dividers 58A-C maintain the separation between the process and instrument chambers 60, 62, regardless of the position of the first and second movable rails 30, 32.
  • first, second, and third dividers 58A-C are substantially identical.
  • the following description of the first, second, and third dividers 58A-C refers to Figures 7-10, which show the first divider 58A in detail.
  • Figures 7-10 are exemplary in nature and directly correspond to the second and third dividers 58B and 58C. Therefore, Figures 7-10 may be viewed to ascertain details pertaining to the second and third dividers 58B and 58C in the same way the Figures 7-10 are viewed to ascertain details pertaining to the first divider 58A.
  • Each of the first, second, and third dividers 58A-C may comprise a plurality of alternating upper pleats 64A-C and lower pleats 66A-C that are configured to open when expanded (as shown in Figure 7) and close when contracted (as shown in Figure 8).
  • the upper pleats 64A-C and the lower pleats 66A-C may extend along the second axis A2 to facilitate expansion and contraction of the first, second, and third dividers 58A-C along the first axis A1.
  • the alternating upper pleats 64A-C and lower pleats 66A-C form a zig-zag configuration (as shown in Figures 9 and 10), with expansion of the dividers 58A-C caused by the widening of the angles of the upper pleats 64A-C and the lower pleats 66A-C and with the contraction of the dividers 58A- C caused by the narrowing of the angles between the upper pleats 64A-C and the lower pleats 66A-C.
  • the dividers 58A-C may be extended until the upper pleats 64A-C and the lower pleats 66A-C have angles of approximately 180 degrees (i.e.
  • the dividers 58A-C may be contracted until the upper pleats 64A-C and the lower pleats 66A-C have angles of approximately zero degrees (i.e., contracted until the upper pleats 64A-C and the lower pleats 66A-C completely closed and folded tight).
  • Each of the first, second, and third dividers 58A-C may have a compression ratio at least 10:1.
  • the compression ratio refers to the ratio of the maximum length of each divider when fully expanded in comparison to the minimum length of each divider when completely contracted. Therefore, each of the dividers 58A-C are capable of extending at least 10 times longer when fully expanded than when fully contracted.
  • the example shown in the Figures is configured to have a compression ratio of approximately 11 :1.
  • the larger the compression ratio the greater the range of movement of the first and second print heads 34, 36 within the cavity 24, which allows the print heads 34, 36 to move over a larger portion of the print bed 56.
  • the potential size of the additive printed part(s) increases as well.
  • each of the first, second, and third dividers 58A-C may comprise a plurality of strips 68A-C that are sequentially disposed such that each strip 68A-C partially defines one of the upper pleats 64A-C and one of the lower pleats 66A-C.
  • each of the strips 68A-C may comprise a body 70A-C extending to opposing upper contact walls 72A-C and lower contact walls 74A-C, with the upper contact walls 72A-C of adjacent strips 68A-C joined to one another at the upper pleat 64A-C and with the lower contact walls 74A-C of adjacent strips 68A-C joined to one another at the lower pleat 66A-C.
  • the adjacent upper contact walls 72A-C and adjacent lower contact walls 74A-C may be joined together by a mechanical fastener 76A-C, as shown in Figure 10.
  • the mechanical fastener 76A-C may be further defined as thread, with adjacent strips 68A-C joined to another by sewing.
  • the adjacent strips 68A-C may be joined in any other suitable manner, including chemical bonding, welding, etc.
  • joining the plurality of strips 68A-C allow for a greater compression ratio than folding one large piece of the same material to form the upper pleats 64A-C and the lower pleats 66A-C. More specifically, folding material often causes bunching along the inner radius of the folds, which correspondingly enlarges the outer radius. As such, the outer radius is often greater than the thickness of the material, which inhibits the ability of the adjacent folds to lie fully against one another and limits the compression ratio.
  • the plurality of strips 68A-C utilized in this example have a consistent thickness from upper pleat 64A-C to the lower pleat 66A-C, which facilitate the compression ratio described above. Furthermore, in this example the strips 68A-C have a thickness T1 (as shown in Figure 9) of approximately 0.7mm- 0.8mm to further facilitate the compression ratio described above.
  • the three-dimensional printer 20 may further comprise a plurality of support members 78A-C individually disposed in the lower pleats 66A-C to retain the first, second, and third dividers 58A-C in a substantially planar configuration along the first and second axes A1 , A2. Said differently, the support members 78A-C provide rigidity to the first, second, and third dividers 58A-C, which reduces the amount of sagging that occurs from the dividers 58A-C spanning the cavity 24.
  • the support members 78A-C may be comprised of spring steel, which generally has a high yield strength that both supports the dividers 58A-C and allows the support members 78A-C to return to their original shape despite deflection and twisting due to loads exerted on the support members 78A-C by the weight of the dividers 58A- C.
  • the support members 78A-C may be comprised of other materials that are capable of retaining the first, second, and third dividers 58A-C in a substantially planar configuration along the first and second axes A1 , A2, including carbon fiber, polymers, ceramics, etc.
  • Each support member 78A-C may have a thickness T2 of 0.1mm - 0.3mm. As best illustrated in Figure 9, each support member 78A-C has a thickness T2 of approximately 0.2mm. The thickness T2 of the support member 78A-C is smaller than the approximately 0.7mm-0.8mm thickness T1 of the strips 68A-C, as described above. As such, the support members 78A- C marginally increase the compression ratio of the dividers 58A-C in comparison to dividers 58A-C with strips 68A-C but without support members 78A-C.
  • the support members 78A-C and the lower contact walls 74A-C may each have a cross-sectional area.
  • each support member 78A-C may be greater than the cross-sectional area of each lower contact wall 74A-C to resist bending. To achieve the larger cross-sectional area, the than the lower contact walls 74A-C, the support members 78A-C extend upwardly beyond contact walls (i.e. , a greater distance than the contact walls).
  • each support member 78A-C may define a plurality of holes 80A-C extending therethrough, with adjacent strips 68A-C joined together through the holes 80A-C to couple together the strips 68A-C and the supports. More specifically, the support members 78A-C may be individually disposed between adjacent strips 68A-C and mounted to the respective lower contact walls 74A-C. The plurality of holes 80A-C provides access to the adjacent lower contact walls 74A-C through the support member 78A-C for fastening therethrough by sewing (as described above) or any other suitable manner of joining.
  • the first, second, and third dividers 58A-C may be comprised of an insulative material to reduce thermal transmission between the process and instrument chambers 60, 62.
  • the process chamber 60 is the region in which the additive printed part(s) are formed while the instrument chamber 62 houses components that control the operation of the first and second print heads 34, 36.
  • the three-dimensional printer 20 may further comprise a printed circuit board 82 disposed in the instrument chamber 62 (as shown in Figures 2 and 3) and operably coupled to at least one of the first and second print heads 34, 36. Printed circuit boards are sensitive to high heat.
  • the process chamber 60 may be heated to control the rate of cooling of the molten filament material when deposited in order to improve the quality of the additive printed part (e.g., strength and appearance).
  • the process chamber 60 is configured to be heated up to approximately 180 degrees Celsius.
  • the desired maximum temperature of the instrument chamber 62 is approximately 50 degrees Celsius.
  • the insulative material of the first, second, and third dividers 58A-C reduces thermal transmission from the process chamber 60 to the instrument chamber 62.
  • the dividers 58A-C limit convective and radiative heat transfer between the chambers.
  • Convective heat transfer refers to heat transfer that takes place within a fluid.
  • the fluid is the air within the cavity 24, with convective heating occurring when the air moves from the process chamber 60 to the instrument chamber 62.
  • Radiative heating refers to heat transfer that occurs due to the movement of energized electromagnetic waves.
  • the insulative material is further defined as a carbon-aramid fabric 84A-C having an aluminized coating 86A-C facing the process chamber 60, as shown in Figure 9.
  • the carbon-aramid fabric 84A-C extends across the cavity 24 (as described above), which provides a physical barrier to limit fluid flow between the chambers and corresponding convective heating.
  • the aluminized coating 86A-C facing the process chamber 60 (as shown in Figure 4) can reflect electromagnetic waves that occur within the process chamber 60 back into the process chamber 60, rather than the waves transmitting through the non-reflective carbon-aramid fabric 84A-C.
  • the dividers 58A-C are not limited to the materials described herein and may be constructed of any suitable materials for reducing heat transfer between the process and instrument chambers 60, 62.
  • each of the first and second movable rails 30, 32 may comprise a pair of tracks 88A-B, 90A-B extending parallel one another with the print heads 34, 36 disposed between and movably coupled to the tracks 88A-B, 90A-B.
  • the pair of tracks 88A-B, 90A-B widen the support for the print heads 34, 36, which stabilize the print heads 34, 36.
  • the tracks 88A-B, 90A-B also define a space therebetween, through which the nozzle 46, 48 extends into the process chamber 60. However, the space between the tracks 88A-B, 90A-B provides access between the process and instrument chambers 60, 62.
  • the each of the first and second movable rails 30, 32 may comprise a pair of rail dividers 92A-B, 94A-B disposed between the pair of tracks 88A-B, 90A-B on opposing sides of the print head 34, 36.
  • one of the rail dividers 92A, 94A is coupled to the print head 34, 36 and extends to the first fixed rail 26 while the other one of the rail dividers 92B, 94B is coupled to the print head 34, 36 and extends to the second fixed rails 26, 28.
  • the pair of rail dividers 92A-B, 94A-B are arranged to expand and contract with the movement of the print head 34, 36 along the movable rail.
  • Each of the rail dividers 92A-B, 94A-B may comprise a plurality of alternating upper pleats 96A-
  • the rail dividers 92A-B, 94A-B may be constructed in the same manner and of the same material as described above for the first, second, and third dividers 58A-C.
  • rail dividers 92A-B, 94A-B are not limited to manner of construction and the materials described herein and may be constructed in any manner and with any suitable materials separating the process and instrument chambers 60, 62.
  • the dividers 58A-C of the present disclosure offer several advantages. These advantages include serving as a barrier between the process and instrument chambers 60, 62 that protects the relatively delicate components disposed in the instrument chamber 62. Not only do the dividers 58A-C provide a physical barrier between the chambers 60, 62, the dividers 58A-C also provide a thermal barrier.
  • the dividers 58A-C are comprised of an insulative material that reduces thermal transmission between the process and instrument chambers 60, 62, maintaining the temperature in the instrument chamber 62 (where the sensitive electronics of the print heads 34, 36 are present) at or below 50 degrees Celsius, even though the process chamber 60 may reach temperatures of 180 degrees Celsius.
  • the three-dimensional printer 20 further comprises at least one wiper assembly 142 for cleaning the excess material off the nozzle 46, 48 of the print head 34, 36, as shown in Figures 11-15.
  • the excess material may develop at the nozzle 46, 48 several different reasons.
  • the print head 34, 36 is paused during a printing operation (such as alternating between the first and second print heads 34, 36 to print a single part) or stopped after completion of a printing operation, the molten filament may seep from the tip 50, 52 of the nozzle 46, 48 due to remaining pressure within the nozzle 46, 48 from the extruder.
  • drool This seepage is commonly referred to in the art as “drool.”
  • This drool can become hardened on the tip 50, 52, making the flow of molten filament through the nozzle 46, 48 difficult.
  • liquid drool may be disposed on the tip 132 may detach during a subsequent print operation and produce a flaw in the printed part.
  • the excess material may also develop at the nozzle 46, 48 during what is referred to as a purge and prime operation prior to a printing operation.
  • a purge and prime operation heats the nozzle 46, 48 to melt the filament therein and forces a selected amount of molten filament through the tip 50, 52 as scrap immediately prior to the print operation.
  • the purge and prime operation serves to remove filament within the nozzle 46, 48 from the previous print operation (which may be a different material composition or color than what is desired for the new print operation) and force new molten filament through the nozzle 46, 48 to ensure that little to no air is present in the nozzle 46, 48.
  • the first molten filament that is deposited from the nozzle 46, 48 during the print operation is the same quality as the molten filament that is deposited from the nozzle 46, 48 later in the print operation.
  • the removal of the excess material from the tip 50, 52 of the nozzle 46, 48 is important to ensure the quality of the printed part.
  • the wiper assembly 142 is disposed in the cavity 24 and is mounted to the housing 22.
  • the wiper assembly 142 comprises a collection bin 144 and a chute 146 having a first end 148 coupled to the collection bin 144 and a second end 150 spaced from the collection bin 144.
  • the chute 146 and the collection bin 144 collectively serve as a receptacle for the excess material that is removed from the nozzle 46, 48. More specifically, the chute 146 receives and guides the excess material toward the collection bin 144. As shown in Figure 11 , the chute 146 extends angularly upward from the collection bin 144. As such, gravity forces the excess the material to slide down the chute 146 and into the collection bin 144.
  • the chute 146 may be disposed at other angles relative to the collection bin 144 other than the angle shown in the Figures, including horizontal, angled downward, curved, etc.
  • the excess material may be transported to the collection bin 144 by manners other than gravity.
  • the chute 146 may be coupled to a pump or a vacuum that moves fluid through the chute 146. The moving fluid could move the excess material through the chute 146 to the collection bin 144.
  • a mechanism (such as an auger) may be disposed in the chute 146 and configured to move the excess material to the collection bin 144.
  • the collection bin 144 serves as a repository for the excess material.
  • the excess material removed from numerous uses of the wiper assembly 142 may be stored within the collection bin 144. At some point the collection bin 144 will become filled with the excess material. A user may empty the excess material from the collection to be disposed of or recycled.
  • the wiper assembly 142 further comprises a blade 158 having a planar configuration and disposed at the second end 150 of the chute 146.
  • the blade 158 extends upwardly along the third axis A3, orthogonal to both the first and second axes A1 , A2, and is arranged to contact the tip 132 of the nozzle 46, 48 and bend as the print head 34, 36 passes over the blade 158 and forcefully remove the material as the nozzle 46, 48 moves past the blade 158 and elastically returns to the planar configuration.
  • the resistance of the blade 158 to bending i.e.
  • internal bias causes the blade 158 to snap back into the planar configuration after the blade 158 is deflected by the nozzle 46, 48 and slides off the tip 132 as the nozzle 46, 48 moves past blade 158.
  • the potential energy in the blade 158 increases as the nozzle 46, 48 moves across the blade 158, until the end of the blade 158 slips off the tip 132 of the nozzle 46, 48 and the potential energy is converted into kinetic energy.
  • the less rigid excess material is sheered from the nozzle 46, 48 due to the sudden kinetic force and is slung off nozzle 46, 48 into the chute 146.
  • the blade 158 may be comprised of spring steel, which generally has a high yield strength that allows the blade 158 to return to its original shape despite deflection and twisting due to loads exerted on the blade 58 by the nozzle 46, 48.
  • the blade 158 may be comprised of other materials that are capable of deflecting and returning to the planar configuration, including other metals, carbon fiber, polymers, etc.
  • the wiper assembly 142 further comprises a brush 160 disposed at the second end 150 of the chute 146, with the brush 160 extending upwardly along the third axis A3 and arranged to contact the tip 132 of the nozzle 46, 48 and wipe off remaining material as the print head 34, 36 passes over the brush 160, after the blade 158.
  • the brush 160 may be comprised of a plurality of bristles 162 extending in substantially linear configurations that are configured to independently bend around and rub against the nozzle 46, 48. As such, the bristles 162 rub against a greater surface area of the nozzle 46, 48, which facilitate removal of remaining excess material disposed on the nozzle 46, 48.
  • the bristles 162 may be sized to partially extend into the nozzle 46, 48 and remove some of the excess material within.
  • the bristles 162 may be comprised of spring steel, allowing the bristles 162 to return to their original shape despite deflection and twisting due to loads exerted on the bristles 162 by the nozzle 46, 48.
  • the bristles 162 may be comprised of other materials that are capable of deflecting and returning to the linear configuration, including other metals, carbon fiber, polymers, etc.
  • the bristles 162 may further comprise a polymeric coating on the spring steel, such as polytetrafiuoroethylene (“PTFE”), that reduces friction between the brush 160 and the nozzle 46, 48 to prevent marring of the nozzle 46, 48, It is to be appreciated that polymeric and non-polymeric coatings may be utilized.
  • PTFE polytetrafiuoroethylene
  • the blade 158 and the brush 160 are mounted within the cavity 24 at a fixed position along the first, second, and third axes A1 , A2, A3.
  • the print head 34, 36 is configured to move along the first and second axes A1 , A2.
  • the print head 34, 36 is fixed relative to the third axis A3. Therefore, the blade 158 and the brush 160 are positioned within the cavity 24 at location that ensures that the print head 34, 36 may move along the first and second axes A1 , A2 to contact both the blade 158 and the brush 160.
  • the nozzle 46, 48 extends down to the tip 132 along the third axis A3, while the blade 158 and the brush 160 extends up along the third axis A3. Portions of the blade 158 and the brush 160 overlap the nozzle 46, 48 along the third axis A3 to ensure contact with the nozzle 46, 48.
  • the blade 158 overlaps a portion of the tip 132 of the nozzle 46, 48 along the third axis A3, which ensures the blade 158 contacts and bends with the movement of the nozzle 46, 48.
  • the blade 158 does not extend exceedingly high on the nozzle 46, 48 such as to exert to great a force on the nozzle 46, 48 that could inhibit movement of the print head 34, 36.
  • the brush 160 extends above the blade 158 such that the brush 160 contacts the nozzle 46, 48 above the blade 158.
  • the height of the blade 158 and the brush 160 may different than what is shown in Figures.
  • the blade 158 and the brush 160 may configured to be adjustable along the third axis A3. More specifically, a user may collectively or independently adjust the heights of the blade 158 and the brush 160 along the third axis A3. As such, the user can tune the height of the blade 158 and the brush 160 to optimize the ability of the blade 158 and the brush 160 to remove the excess material from the nozzle 46, 48.
  • the blade 158 and the brush 160 are adjacent one another (i.e., next to one another, back-to-back). As such, the nozzle 46, 48 may contact both the blade 158 and the nozzle 46, 48 by moving in a linear direction. However, the blade 158 and the brush 160 may be spaced from one another and askew (i.e., angled relative to one another) such that the nozzle 46, 48 must move along a non-linear path to contact both the blade 158 and the brush 160, as shown in Figures 15 through 19.
  • the three-dimensional printer 20 may further comprise a control system 152 in communication with the print head 34, 36.
  • the control system 152 operates the three-dimensional printer 20, which includes the movement of the printer head along the first and second axes A1 , A2, the movement of the build table 54 along the third axis A3, the feeding of the filament to the nozzle 46, 48, the temperature of the cavity 24, etc.
  • the control system 152 moves the print head 34, 36 along a programmed path stored within the control system 152.
  • the programmed path moves within the first and second axes A1 , A2 and runs across the blade 158 and the brush 160.
  • the programmed path must be based upon fixed positions of the blade 158 and the brush 160 along the first and second axes A1 , A2.
  • the blade 158 and the brush 160 are mounted in the cavity 24 and fixed along the first and second axes A1 , A2.
  • the programmed path would have to be modified to ensure contact of the nozzle 46, 48 with the blade 158 and the brush 160.
  • the control system 152 may be configured to move the print head 34, 36 on the programmed path prior to the print head 34, 36 beginning a print operation or after a pause during a print operation to ensure excess material does not become deposited on the print bed 56.
  • the control system 152 may also be configured to move the print head 34, 36 on the programmed path after the print head 34, 36 completes a print operation to ensure the molten excess material disposed on the nozzle 46, 48 does not become hardened and difficult to remove after an extended period of non-use.
  • the control system 152 may move the print head 34, 36 on the programmed path at any suitable time.
  • a user may instruct the control system 152 to move the print head 34, 36 along the programmed path at any time when desired.
  • the print head 34, 36 is further defined as the first and second print heads 34, 36 in the example shown in Figure 1.
  • the wiper assembly 142 may be further defined as a first wiper assembly 142A and a second wiper assembly 142B, both disposed within the cavity 24 and mounted to the housing 22, as shown in Figure 14.
  • the wiper assemblies 142A, 142B include the components of wiper assembly 142 referenced in Figures 11 through 13 as well as in Figures 15 through 19 and are disposed on opposing sides of the housing 22, with the first wiper assembly 142A arranged to remove excess material from the first nozzle 46 of the first print head 34 and the second wiper assembly 142B arranged to remove excess material from the second nozzle 48 of the second print head 36.
  • the first and second wiper assemblies 142A, 142B being disposed on opposing sides of the housing 22 allow one of the print heads 34, 36 to independently remove excess material while allowing the other one of the print heads 34, 36 to continue depositing material across most of the print bed 156. More specifically, if the wiper assemblies 142A, 142B were located adjacent one another or if only one wiper assembly 142 was present to clean both of the first and second print heads 34, 36, the print heads 34, 36 would be in proximity of one another when one of the print heads 34, 36 was moving over the wiper assembly 142, which would limit the surface area of the bed over which the other one of the print heads 34, 36 could operate.
  • first and second wiper assemblies may be disposed anywhere within the housing 22. Furthermore, the first and second wiper assemblies may be configured to operate with any number of wiper assemblies.
  • the wiper assembly 142 (including wiper assemblies 142A, 142B) of the three-dimensional printer 20 offers several advantages.
  • the automated process of removing the excess material by moving the print head 34, 36 across the wiper assembly 142 eliminates the need for a technician to clean the nozzle 46, 48, which eliminates damaging the print head 34, 36 through human error as well as the risk of injuring the technician with the hot components within the three-dimensional printer 20.
  • the automated process of removing the excess material improves the speed at which the nozzle 46, 48 is cleaned, resulting in less downtime of the three-dimensional printer 20 and greater throughput of the printed parts.
  • first and second wiper assemblies 142A, 142B disposed on opposing sides of the housing 22 allow one of the first and second print heads 34, 36 to independently remove excess material, while the other one of the first and second print heads 34, 36 deposit material on most of the print bed 56, which improves the speed of the printer and allows for larger parts to be produced.
  • the three-dimensional printer 20 further comprises a calibration switch 242 mounted to the build table 54.
  • the calibration switch 242 is mounted on a front edge of the build table 54, making the calibration switch 242 accessible for service or replacement by a user.
  • the calibration switch 242 may be mounted to the build table 54 in any suitable location.
  • the calibration switch 242 comprises a base 244, a plunger 246 supported by the base 244 and movable along the third axis A3, and a sensor 248 arranged to detect movement of the plunger 246 along the third axis A3.
  • the base 244 provides a contact surface 250 disposed around the plunger 246 that is planar and parallel to the support bed.
  • the sensor 248 is disposed below the plunger 246 and is actuated by the plunger 246 when the plunger 246 is moved toward the sensor 248.
  • the calibration switch 242 is configured to be resilient to high temperatures. In this example, the temperatures within the cavity 24 of the housing 22 can reach 180 degrees Celsius.
  • the three-dimensional printer 20 further comprises a control system 252 in communication with the print head 34, 36, the build table 54, and the calibration switch 242.
  • the control system 252 operates the three-dimensional printer 20, which includes the movement of the printer head along the first and second axes A1 , A2, the movement of the build table 54 along the third axis A3, the feeding of the filament to the nozzle 46, the temperature of the cavity 24, etc.
  • the control system 252 In order to produce an additive printed part, the control system 252 must know the spatial locations of the build table 54 and the print head 34, 36.
  • control system 252 must know the location of the tip 50, 52 of the nozzle 46, 48 of the print head 34, 36, relative to the build table 54 along the first, second, and third axes A1 , A2, A3. If the build table 54 and the nozzle 46 are misaligned along any of the axes A1 , A2, A3, a poor-quality part may be produced. For example, dispensing material too far above the build table 54 can result inconsistent surface features on the part.
  • Misalignment of the build table 54 and the nozzle 46 can also result in damage to the three-dimensional printer 20 if, for example, the nozzle 46 contacts the print bed 56 due to the nozzle 46, 48 and the build table 54 being closer than the control system 252 believed them to be along the third axis A3.
  • the build table 54 and the print head 34, 36 are configured to move, there are tolerances built into the build table 54 and the print head 34, 36. While these tolerances are necessary for movement, they can vary the relative positions between the build table 54 and the print head 34, 36 along the first, second, and third axes A1 , A2, A3 after each use.
  • the control system 252 is arranged to perform a calibration sequence in which the print head 34, 36 is arranged to move along the first and second axes A1 , A2 over the calibration switch 242 (as shown in Figures 21 A- 21 D), the build table 54 is arranged to move towards and away from the print head 34, 36 as the print head 34, 36 moves over the calibration switch 242 (as shown in Figures 21 B and 21 D), the sensor 248 is arranged to send a signal to the control system 252 when the nozzle 46 contacts and moves the plunger 246, and the control system 252 is arranged to determine a location of the nozzle 46 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 based upon the signal from the sensor 248.
  • the plunger 246 defines a constant reference point from which the relative locations of the build table 54 and the print head 34, 36 can be measured.
  • the contact of the nozzle 46 with the plunger 246 activates the sensor 248 which sends a signal to the control system 252 that the nozzle 46, 48 is at the reference point.
  • the control system 252 determines the actual location of the nozzle 46 along the first and second axes A1 , A2 and the build table 54 along the z-axis, referred to as the zero location.
  • the control system 252 compares the zero location to the previously known zero location of the build table 54 and the print head 34, 36 (i.e., the location known to the control system 252 prior to calibration in the memory of the control system 252) to determine the offset along the first, second, and third axes A1 , A2, A3.
  • the control system 252 then saves the zero location in memory and performs the printing operation based on the new zero location.
  • the calibration sequence is further defined as the print head 34, 36 being arranged to move along the first and second axes A1 , A2 in a calibration pattern 258 over the calibration switch 242 (as shown in Figures 4 and 7), the build table 54 being arranged to cyclically move towards and away from the print head 34 as the print head 34 moves in the calibration pattern 258 over the calibration switch 242 (as shown in Figures 21A-D), the sensor 248 being arranged to send a signal to the control system 252 when the nozzle 46 contacts and moves the plunger 246 as the print head 34, 36 moves in the calibration pattern 258, and the control system 252 being arranged to determine a location of the nozzle 46 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 based upon the signal from the sensor 248.
  • the build table 54 may move up and down a plurality of times to contact the nozzle 46 with the calibration switch 242 and the print head 34, 36 may move along the first and second axes A1 , A2 to touch different portions of the calibration switch 242.
  • the plunger 246 has a surface area, which will always be larger than a point in space from which the zero location can be determined.
  • the zero location is located on the plunger 246, generally at the center of the top surface. Because of this, the control system 252 must find the center of the plunger 246 with the nozzle 46. To do so, the control system 252 contacts the nozzle 46 with the calibration switch 242 at a plurality of points.
  • the nozzle 46 contacts the plunger 246 (as shown in Figure 21 D). At other positions, the nozzle 46 misses the plunger 246 (i.e. , off the perimeter of the plunger 246, around the base 244, as shown in Figure 21 B).
  • the sensor 248 sends a signal to the control system 252 each time the plunger 246 is moved. From this information, the control system 252 finds the outer edge of the plunger 246 and determines the center of the plunger 246, from which the zero location can be determined.
  • the calibration pattern 258 of the print head 34 may be determined by the profile of the plunger 246.
  • the plunger 246 has a contact surface 250 arranged to engage the nozzle 46, with the contact surface 250 having a planar configuration, as shown in Figures 20 and 21 A-D.
  • the calibration pattern 258 of the print head 34 is a cross configuration 260 having a single pass across the calibration switch 242 along the first axis A1 and a single pass across the calibration switch 242 along the second axis A2, as shown in Figure 22.
  • the contact surface 250 has an arcuate configuration.
  • the calibration pattern 258 of the print head 34, 36 is a switch- back configuration 262 having a plurality of reversing passes across the calibration switch 242 along one of the first and second axes A1 , A2 that are progressively spaced from one another along the other one of the first and second axes A1 , A2, as shown in Figure 25.
  • the method of calibrating the zero location for planar and arcuate plunger 246 configurations will be described in greater detail below.
  • the nozzle 46 may be arranged to move along the third axis A3 and print head 34, 36 may further comprise an anti-crash sensor 234 arranged to detect movement of the nozzle 46 along the third axis A3 for preventing damage to the nozzle 46 when contacting an immovable surface, such as the print bed 56. More specifically, the anti-crash sensor 234 detects the movement of the nozzle 46 and sends a nozzle trigger signal to control system 252. The control system 252 stops movement of the build table 54 towards the print head 34, 36 to prevent damage to the nozzle 46. [00133] The anti-crash sensor 234 may be utilized in the calibration sequences described above to confirm that the nozzle 46 did not contact the button.
  • the nozzle 46 misses the plunger 246, the nozzle 46 will eventually contact an immovable surface (such as the base 244 of the calibration switch 242) and the build table 54 continues to rise toward the print head 34, 36. Contact with the immovable surface causes the nozzle 46 to move along the third axis A3. The anti-crash sensor 234 then communicates with the control system 252, confirming that the plunger 246 was not contacted.
  • an immovable surface such as the base 244 of the calibration switch 242
  • Each of the plunger 246 and the nozzle 46 may be biased to resist movement along the third axis A3.
  • the bias may be performed by a mechanical device (e.g., a spring) or through than electrical device (e.g., an electromagnet).
  • the bias of the nozzle 46, 48 may be greater than the bias of the plunger 246 such that the sensor 248 of the calibration switch 242 is arranged to send a signal to the control system 252 prior to the anti-crash sensor 234.
  • the calibration sequence may further comprise the build table 54 being arranged to move towards the print head 34 (as shown in Figure 26A), the sensor 248 of the calibration switch 242 being arranged to send a signal to the control system 252 when the nozzle 46 contacts and moves the plunger 246, the build table 54 arranged to continue movement towards the print head 34 (as shown in Figure 26B), the anti-crash sensor 234 of the nozzle 46 arranged to send a nozzle trigger signal to the control system 252, and the control system 252 arranged to determine a trigger-travel distance of the nozzle 46 along the third axis A3 based upon the movement of the print head 34, 36 between the signal from the calibration switch 242 and the nozzle trigger signal from the anti-crash sensor 234.
  • Determining the trigger-travel distance may be useful to calibrate the location of the nozzle 46 relative to the remainder of the print head 34, 36 along the third axis A3. More specifically, the calibration switch 242 can determine the zero location of the nozzle 46. However, because the nozzle 46 is moveable along the third axis A3 relative to the rest of the print head 34, there are tolerances between the moving parts that can cause variations in the trigger-travel distance between each use. By finding the trigger travel distance, the position of the build table 54 can be adjusted on the third axis A3 to ensure that the tip 52 of the nozzle 46 and the print head 34 as a whole are disposed at the proper zero location on the third axis A3.
  • the nozzle 46 comprises the heater 230 for warming the material.
  • the calibration sequence may determine the trigger-travel distance of the nozzle 46 when warmed by the heater 230 and determines the percent elongation of the nozzle 46. More specifically, when the nozzle 46 is warmed by the heater 230, the nozzle 46 may thermally expand and elongate along the third axis A3. As such, the zero location of the third axis A3 may change when the three-dimensional printer 20 is actively producing an additive printed part.
  • the calibration sequence may warm the heater 230 to induce the elongation of the nozzle 46 and then move the build table 54 up until the anti-crash sensor 234 is activated and sends the nozzle trigger signal to the control system 252, as shown in Figure 23C.
  • the control system 252 may then compare the zero location of the build table 54 along the third axis A3 when the nozzle 46 is not heated to the location of the build table 54 along the third axis A3 when the nozzle 46 is heated to the determine a percent elongation of the nozzle 46 between the two known temperatures. Knowing the percent elongation, the control system 252 can dynamically adjust the location of the build table 54 along the third axis A3 when the three-dimensional printer 20 is producing a part by monitoring the temperature of the nozzle 46.
  • control system 252 may be configured to characterize the thermal expansion of the nozzle.
  • the control system 252 may than store the characterization data in memory.
  • the control system may then later on access the characterization data for use to compensate the trigger travel height and zero location of the build table 54, without necessarily running the process described above.
  • the stored characterization data may also be used for dynamic simulations and specific process tests. For example, when testing different nozzles 46 or materials in specific patterns to check the thickness and height of the deposited material.
  • the at least one print head 34 is further defined as the first print head 34 and the second print head 36 independently movable along the first and second axes A1 , A2 and each comprising a nozzle 46, 48.
  • each of the first and second print heads 34, 36 may be arranged to move over the calibration switch 242 to determine the locations of the nozzles 46, 48 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 based upon the signal from the sensor 248.
  • a method of calibrating the above-described three- dimensional printer 20 comprises moving the print head 34, 36 along the first axis A1 and the second axis A2 over the calibration switch 242 as shown between Figures 21 A and 21 C.
  • the method further comprises moving the build table 54 towards the print head 34, 36 as the print head 34, 36 moves over the calibration switch 242 and moving the plunger 246 of the calibration switch 242 with the nozzle 46 of the print head 34, 36, as shown in Figure 21 D.
  • the method further comprises sensing the movement of the plunger 246 with the sensor 248 of the calibration switch 242, sending the signal from the sensor 248 to the control system 252, and determining a location of the nozzle 46 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 based upon the signal from the sensor 248.
  • Moving the print head 34, 36 may be further defined as moving the print head 34, 36 in the above-mentioned calibration pattern 258 over the calibration switch 242 as shown in Figures 22 and 25.
  • Moving the build table 54 towards the print head 34, 36 may be further defined as moving the build table 54 cyclically towards and away from the print head 34, 36 as the print head 34, 36 moves in the calibration pattern 258 over the calibration switch 242 as shown between Figures 21A-D.
  • moving the plunger 246 of the calibration switch 242 with the nozzle 46 of the print head 34, 36 may be further defined as repeatedly moving the plunger 246 of the calibration switch 242 toward and away from the base 244 along the third axis A3 with the nozzle 46 of the print head 34, 36.
  • Sensing the movement of the plunger 246 with the sensor 248 of the calibration switch 242 may be further defined as sensing each movement of the plunger 246 toward the base 244 with the sensor 248 of the calibration switch 242.
  • Sending the signal from the sensor 248 to the control system 252 may be further defined as sending the signal from the sensor 248 to the control system 252 each time the nozzle 46, 48 contacts and moves the plunger 246 toward the base 244.
  • Determining the location of the nozzle 46, 48 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 based upon the signal from the sensor 248 may be further defined as determining the location of the nozzle 46, 48 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 with an algorithm based upon the signals from the sensor 248.
  • the plunger 246 has the contact surface 250 arranged to engage the nozzle 46, 48.
  • the contact surface 250 has the planar configuration.
  • moving the print head 34, 36 in the calibration pattern 258 over the calibration switch 242 is further defined as moving the print head 34, 36 in the cross configuration 260 having the single pass across the calibration switch 242 along the first axis A1 and the single pass across the calibration switch 242 along the second axis A2, as shown in Figure 22.
  • the nozzle 46, 48 will move the plunger 246 when disposed over the plunger 246 on the first and second axes A1 , A2 and will miss the plunger 246 when not disposed over the plunger 246.
  • determining the location of the nozzle 46 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 with an algorithm based upon the signals from the sensor 248 may be further defined as determining the location of the nozzle 46, 48 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 by finding a midpoint of first axis values from the signals generated along the single pass on the first axis A1 to generate a zero first axis location of the nozzle 46, 48, finding a midpoint of second axis values from the signals generated along the single pass on the second axis A2 to generate a zero second axis location of the nozzle 46, 48, and finding an average of third axis values from the signals generated along both of the passes on the first and second axes A1 , A2 to generate a zero third axis location of the nozzle 46, 48.
  • the control system 252 reviews the signals from the sensor 248 when the nozzle 46, 48 moved the plunger 246 as the nozzle 46, 48 moved along the first axis A1 . Based upon the first and last time the plunger 246 was depressed while the nozzle 46, 48 moved along the first axis A1 (which would signify the edges of the button), the control system 252 can then determine the midpoint between the first and last signal as the zero first axis location. Likewise, the control system 252 reviews the signals from the sensor 248 when the nozzle 46, 48 moved the plunger 2246 as the nozzle 46, 48 moved along the second axis A2.
  • the control system 252 can then determine the midpoint between the first and last signal as the zero second axis location.
  • the control system 252 reviews all signals from the sensor 248 when the nozzle 46, 48 moved the plunger 246 (along both the first and second axes A1 , A2).
  • the control system 252 then averages the locations of the nozzle 46, 48 on the third axis A3 from the signals and determines the zero third axis location.
  • the control system 252 compares the zero location to the previously-known zero location of the build table 54 and the print head 34, 36 (i.e., the location known to the control system 252 prior to calibration in the memory of the control system 252) to determine the offset along the first, second, and third axes A1 , A2, A3.
  • the control system 252 then saves the zero location in memory and performs the printing operation based on the new zero location.
  • the contact surface 250 of the plunger 246 has the arcuate configuration.
  • Moving the print head 34, 36 in the calibration pattern 258 over the calibration switch 242 is further defined as moving the print head 34, 36 in the switch-back configuration 262 having the plurality of reversing passes across the calibration switch 242 along one of the first and second axes A1 , A2 that are progressively spaced from one another along the other one of the first and second axes A1 , A2, as shown in Figure 25.
  • the switch-back configuration 262 produces a grid of points across the calibration switch 242 at which the build table 54 moved toward the nozzle 46.
  • the plunger 246 is arcuate, the edges of the plunger 246 are not clearly defined, making a midpoint determination difficult. Furthermore, because the tip 232 of the nozzle 46, 48 has an annular opening 136 (see Figure 24) that the plunger 246 can move up into, the amount of travel to depress the plunger 246 can vary across the first and second axes A1 , A2.
  • determining the location of the nozzle 46 along the first, second, and third axes A1 , A2, A3 in relation to the build table 54 with an algorithm based upon the signals from the sensor 248 may be further defined as averaging the first axis values and the second axis value to find an estimated zero location of the nozzle 46, 48 on the plunger 246, using the estimated zero location to run a smaller, finer calibration sequence with the switch-back configuration 262 around the estimated zero location.
  • the method further comprises finding a global minimum third axis value from the signals, which corresponds to the annular opening 236 of the tip 50 being located on the center of the arcuate plunger 246, and assigning a new estimated zero location of the nozzle 46, 48 on the plunger 246.
  • the method may further comprise using the new estimated zero location to run a smaller, finer calibration sequence with the switch-back configuration 262 around the new estimated zero location for validation.
  • the control system 252 then compares the new estimated zero location to the previously-known zero location of the build table 54 and the print head 34, 36 (i.e., the location known to the control system 252 prior to calibration in the memory of the control system 252) to determine the offset along the first, second, and third axes A1 , A2, A3.
  • the control system 252 then saves the zero location in memory and performs the printing operation based on the new zero location.
  • the nozzle 46 may be arranged to move along the third axis A3 and print head 34, 36 further comprises the above-mentioned anti-crash sensor 234 arranged to detect movement of the nozzle 46 along the third axis A3, with each of the plunger 246 and the nozzle 46, 48 biased to resist movement along the third axis A3, and with the bias of the nozzle 46, 48 being greater than the bias of the plunger 246 such that the sensor 248 of the calibration switch 242 is arranged to send the signal to the control system 252 prior to the anti-crash sensor 234.
  • the method further comprises continuing to move the build table 54 towards the print head 34, 36 after completely moving the plunger 246 of the calibration switch 242 (see Figure 26A), moving the nozzle 46, 48 along the third axis A3 (see Figure 26B), and sensing the movement of the nozzle 46, 48 with the anti-crash sensor 234.
  • the method further comprises sending the nozzle trigger signal from the anti-crash sensor 234 to the control system 252 and determining the trigger-travel distance of the nozzle 46, 48 along the third axis A3 based upon the movement of the print head 34, 36 between the signal from the calibration switch 242 and the nozzle trigger signal from the anti-crash sensor 234.
  • the nozzle 46, 48 may comprise the heater 230 for warming material to form an additive printed part, as shown in Figure 26C.
  • the method comprises warming the nozzle 46, 48 with the heater 230, moving the build table 54 towards the print head 34, 36, and moving the plunger 246 of the calibration switch 242 with the nozzle 46, 48 of the print head 34, 36.
  • the method further comprises continuing to move the build table 54 towards the print head 34, 36 after completely moving the plunger 246 of the calibration switch 242, moving the nozzle 46, 48 along the third axis A3 (see Figure 8C), sensing the movement of the nozzle 46, 48 with the anti-crash sensor 234, sending the heated nozzle trigger signal from the anti-crash sensor 234 to the control system 252, and determining the heated trigger-travel distance of the nozzle 46, 48 along the third axis A3 based upon the movement of the print head 34, 36 between the signal from the calibration switch 242 and the heated nozzle trigger signal from the anti-crash sensor 234.
  • the method further comprises comparing the trigger-travel distance (see Figure 26B) with the heated trigger-travel distance (see Figure 26C) to determine the percent elongation of the nozzle 46, 48 along the third axis A3.
  • the at least one print head 34, 36 is further defined as the first print head 34 and the second print head 36 independently movable along the first and second axes A1 , A2 and each comprising the nozzle 46, 48.
  • moving the print head 34, 36 over the calibration switch 242 may be further defined as moving one of the first and second print heads 34, 36 over the calibration switch 242.
  • the method may further comprise moving the other one of the first and second print heads 34, 36 over the calibration switch 242.
  • the calibration switch 242 and the corresponding method calibrating the three-dimensional printer 20 with the calibration switch 242 offers several advantages.
  • the calibration process can be done with depositing material on the build table 54, which eliminates the waste that commonly occurs during calibration.
  • the use of the calibration switch 242 with the anti-crash sensor 234 allows for dynamic adjustment to the location of the build table 54 along the third axis A3 when the three-dimensional printer 20 is producing a part by monitoring the temperature of the nozzle 46, 48, which improves the quality of the printed part throughout the entire printing process.

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EP22796623.1A 2021-04-27 2022-04-27 Dreidimensionaler drucker Pending EP4323193A1 (de)

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US202163180438P 2021-04-27 2021-04-27
US202163180437P 2021-04-27 2021-04-27
US17/241,843 US11642845B2 (en) 2021-04-27 2021-04-27 Three-dimensional printer comprising first and second print heads and first, second, and third dividers
PCT/US2022/026507 WO2022232248A1 (en) 2021-04-27 2022-04-27 Three-dimensional printer

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US20230211553A1 (en) * 2021-12-30 2023-07-06 Stratasys, Inc. Method of moving a print head between a plurality of partitioned chambers in an additive manufacturing system

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US6007318A (en) * 1996-12-20 1999-12-28 Z Corporation Method and apparatus for prototyping a three-dimensional object
JP6316991B2 (ja) * 2014-06-20 2018-04-25 ヴェロ・スリー・ディー・インコーポレイテッド ３次元物体を生成するための方法
US9943886B2 (en) * 2014-12-04 2018-04-17 Xerox Corporation Ejector head cleaning cart for three-dimensional object printing systems
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