EP4727752A2

EP4727752A2 - Multi axis movement for multicomponent reactive extrusion printing

Info

Publication number: EP4727752A2
Application number: EP24841809.7A
Authority: EP
Inventors: Bret Michael BOYLE; Kerianne Merceline DOBOSZ; Christian CANCINO; Peter Kenneth YOCHIM; Jeffrey Scott WARZYNSKI; Anna Carmella IACOVINO; Michael Anthony BUBAS
Original assignee: PPG Industries Ohio Inc
Current assignee: PPG Industries Ohio Inc
Priority date: 2023-06-13
Filing date: 2024-04-09
Publication date: 2026-04-22
Also published as: KR20260021058A; WO2025048900A2; WO2025048900A9; CN121335797A; WO2025048900A3; IL324974A

Abstract

An additive manufacturing system comprising a multi-axis additive manufacturing device and rotating/tilting print bed for multiple axis movement for multicomponent reactive extrusion printing and a method of use.

Description

MULTI AXIS MOVEMENT FOR MULTICOMPONENT REACTIVE EXTRUSION

PRINTING

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 63/507,879 entitled “MULTI AXIS MOVEMENT FOR MULTICOMPONENT REACTIVE EXTRUSION PRINTING”, filed on June 13, 2023, which is incorporated by reference in its entirety.

GOVERNMENT LICENSE RIGHTS

[0002] This invention was made with government support under Government Contract No. W91 INF- 17-2-0227 Additive Manufacturing (U.S. Army Research Laboratory, ARL). The government may have certain rights in the invention.

FIELD

[0003] The present disclosure relates to multiple axis additive manufacturing system comprising a multi-axis additive manufacturing device and rotating/tilting print bed for multiple axis movement for multicomponent reactive extrusion printing.

BACKGROUND

[0004] 3D printing is a process that is used to create objects out of cured compositions, such as plastics. The cured composition can be made of a thermoset composition. During the printing of the object using a thermoset composition, at least two coreactive components are mixed together to create a coreactive composition, or printable composition. The thermoset composition may be used in ambient reaction extrusion (ARE) printing, in which the coreactive composition is deposited by a printhead onto a printing bed using an additive manufacturing device and cured at ambient conditions.

[0005] When printing using an additive manufacturing device that moves along a maximum of three axes and a fixed print bed, support structures may be needed to support portions of the 3D printed object that may droop, sag, or otherwise move due to gravity. Moving the additive manufacturing device in only two axes may limit the shapes and angles created and lengthen printing time due to printing support structures. SUMMARY

[0006] The present disclosure provides a method of printing a 3D article comprising: combining a first coreactive component and second coreactive component in a mixing arrangement of a printhead coupled to a multi-axis movable manipulator, the first coreactive component and the second coreactive component reacting to form a first printable composition; moving the printhead while extruding the first printable composition to print a first portion of a 3D printed article onto a print bed with the print bed disposed in a first orientation; moving the print bed to a second orientation which is non-parallel to the first orientation; and moving the printhead while extruding the first printable composition to print a second portion of the 3D printed article onto the first portion of the 3D printed article. The first portion of the 3D printed article is printed along a first axis and the second portion of the 3D printed article is printed along a second axis, the second axis being non-parallel with the first axis.

[0007] The present disclosure further provides an additive manufacturing system for printing 3D objects comprising a multi-axis movable manipulator and a tillable and rotatable print bed. The multi-axis movable manipulator comprises: a base fixed to a surface; a first arm rotatably coupled to the base; a second arm rotatably coupled at a proximal end of the second arm to the first arm; and a printhead rotatably coupled to a distal end of the second arm. The first and second arm are each configured to rotate about different axes of rotation such that the multi-axis movable manipulator may move along at least four axes of rotation. The tiltable and rotatable print bed comprises: a base fixed to an anchoring surface; and a print surface coupled to the base. The print surface is configured to tilt between a horizontal position and a non-horizontal position and also rotate about an axis.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings. These above-mentioned and other features of the disclosure may be used in any combination or permutation.

[0009] FIG. 1 is a front view of an additive manufacturing system comprising a multiaxis additive manufacturing device and a rotating print bed for multiple axis movement 3D printing; [0010] FIG. 2 is a perspective view of a printhead coupled to a distal end of the multiaxis additive manufacturing device of FIG. 1 ;

[0011] FIG. 3 is a perspective view of a multi-component printhead on the end of the multi-axis additive manufacturing device of FIG. 1 ;

[0012] FIG. 4 is a cross-sectional view along axis A of the multi-component printhead of FIG. 3 ;

[0013] FIG. 5 is a front perspective view of a mixing arrangement within a diamond mount of the multi-component printhead device of FIG. 3;

[0014] FIG. 6 is a flowchart illustrating a method of printing a 3D object using the multi-component printhead of FIG. 3;

[0015] FIG. 7 is a flowchart illustrating a method of printing a 3D object using the multi-component printhead of FIG. 3;

[0016] FIG. 8A is an illustration of an additive manufacturing device and fixed print bed printing a 3D object with support structures; and

[0017] FIG. 8B is an illustration of the additive manufacturing device and rotating print bed of FIG. 1 printing a 3D object without support structures.

[0018] FIG. 9A is an illustration of a 3D printed object with a portion of the structure comprising an overhang;

[0019] FIG. 9B is an illustration of printing a bottom portion of the 3D object of FIG.

9A;

[0020] FIG. 9C is an illustration of further printing the bottom portion of the 3D object of FIG. 9B;

[0021] FIG. 9D is an illustration of rotating the print bed to print a top portion of the 3D object of FIG. 9 A without support structures;

[0022] FIG. 9E is an illustration of rotating the print bed to further print the top portion of the 3D object of FIG. 9D without support structures;

[0023] FIG. 10A is an illustration of printing limitations of an additive manufacturing device with a limited range of motion;

[0024] FIG. 10B is an illustration of how the additive manufacturing system of FIG. 1 can print a 3D object without printing limitations;

[0025] FIG. 11 A is an illustration of a first method of printing a 3D object by rotating the multi-axis additive manufacturing device and fixing the print bed of FIG. 1 ; [0026] FIG. 11B is an illustration of a second method of printing a 3D object by rotating the print bed of FIG. 1 ;

[0027] FIG. 12A is an illustration of fixed printing using an additive manufacturing device;

[0028] FIG. 12B is an illustration of conformal printing using the additive manufacturing device of FIG. 1 ;

[0029] FIG. 13 is a perspective side-view of the rotating and tilting print bed of FIG. 1 ; and

[0030] FIG. 14 is an illustration of a schematic for a computer system for additive manufacturing.

[0031] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate the disclosure, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.

DETAILED DESCRIPTION

[0032] The present disclosure provides a multiple axis additive manufacturing system comprising a multi-axis additive manufacturing device and rotatable and tiltable print bed. [0033] I. Definitions

[0034] For purposes of the following detailed description, it is to be understood that the disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term "about." For example, numerical ranges provided for weight percentages of components or amounts of components added should be construed as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0035] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0036] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges from (and including) the recited minimum value of 1 to the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0037] The use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, the use of "or" means "and/or" unless specifically stated otherwise, even though "and/or" may be explicitly used in certain instances.

[0038] “Printing” refers to any process in which a material is deposited onto and/or reacted with another material and/or itself, for example three-dimensional printing.

[0039] “Coreactive composition” refers to a composition comprising at least two different compounds capable of chemically reacting with each other to form covalent bonds. [0040] “Coreactive component” refers to a compound containing at least one reactive functional group, that when combined with a chemically compatible functional group, reacts to form a coreactive composition.

[0041] “Reactive functional group” refers to a chemical group capable of chemically reacting with another reactive functional group to form a covalent bond.

[0042] “Reactive compound” refers to a compound comprising at least one reactive functional group.

[0043] “Extrusion” refers to a process used to create objects in which material is pushed through a die. An extrusion die has a shape and dimensions suitable to build an object. An extrusion die may have a fixed shape or a shape that can be changed during extrusion.

[0044] “Filler” refers to any compound added to a reactive compound or coreactive composition that is nonreactive with at least a part of the compound and/or composition. Fillers as used herein encompasses particulates, fibers, slurries, mixtures, and any other compound and combinations thereof that may be added to a reactive compound and/or coreactive composition. [0045] “ARE” or ambient reactive extrusion refers to any additive manufacturing of printable composition including coreactive components.

[0046] “Ambient conditions” refers to room temperature (e.g., about 20 °C to 28 °C, such as 23 °C), at or near 45% relative humidity, and atmospheric pressure (e.g., 1 atm). [0047] II. Coreactive Chemistries

[0048] Additive manufacturing using coreactive compositions, also referred to as ambient reactive extrusion, or ARE type three-dimensional printing, typically utilizes at least two components that react with each other (e.g., are coreactive). A first coreactive component (sometimes referred to herein as a first reactant group, a first reactive functional group, part A) and at least one second coreactive component (sometimes referred to herein as a second reactant group, second reactive functional group, part B), when extruded in combination and/or succession, chemically react with one another to form a coreactive composition. The coreactive composition may thereafter cure under ambient conditions or, depending on the chemistry of the reaction, with the assistance of, for example, heat, actinic radiation, catalysts, addition of curing agents-post extrusion, etc. to form an object, or a portion of an object, comprising a thermosetting polymer (sometimes referred to as a thermoset), a thermoplastic polymer, or combinations thereof. At least the first coreactive component and the second coreactive component are chosen by one skilled in the art to result in the desired final product (e.g., thermoset, thermoplastic, etc.).

[0049] Three dimensional objects formed from coreactive compositions are additively manufactured by extruding the coreactive composition, which may be in an at least partially reacted state, onto a surface, such as a build platform. The coreactive composition may be in an at least partially reacted state at the time of extrusion and thereafter fully react and cure to form a layer of the coreactive composition. Successive layers of either the same, or different coreactive compositions can be deposited, forming additional layers of material. The coreactive composition may be at least partially reacted when the coreactive components come together, such as in a mixing volume, just prior to extrusion. Alternatively, the two coreactive components could be premixed before extrusion and treated in a way to arrest the reaction (e.g., arrest curing of the coreactive composition), such as freezing the mixture upon mixing.

[0050] It may be desirable to select the chemistry of each layer of the deposited coreactive composition such that covalent bonds between each successive layer of material are formed. Furthermore, different portions of the article can be printed from different coreactive compositions (e.g., a first coreactive composition printed to form a first portion of the object such as a base portion, an internal structure, etc., and a second coreactive composition printed to form a second portion of the object), and, depending on the chemical reactivity between the different coreactive compositions, covalent bonds might also form between different materials.

[0051] Specifically, an article may be printed so as to have a rigid portion and a flexible portion, a rigid portion and a foam-like portion, a tactile portion and a rigid and/or flexible portion, two portions comprising different densities, one or more conductive portions, one or more thermally/electrically conductive portions, two or more different colors, two or more different rheological profiles, two or more different materials comprising different affinities for water and/or solvent(s), and the like. The article may also be printed such that the coreactive compositions are deposited onto existing articles (e.g., other thermosets and/or thermoplastics, metals, woods, composite materials, ceramics, etc.) resulting in an article comprising both coreactive and non-coreactive compositions.

[0052] Additive manufacturing as described herein may result in an object having higher strength, particularly along the Z (e.g., vertical) axis, as compared to other extruded or printed parts due to the covalent bonding between the printed layers. Strong intralayer and interlayer covalent bonding results in not only stronger parts, but also in more uniform part geometries; that is, less print lines and/or portion differentials. The ability to form, in one process, objects having multiple substrates and/or portions comprising different coreactive or non-coreactive compositions is a further advantage.

[0053] Table 1 describes suitable coreactive compositions and the coreactive components from which they can be formed. These coreactive compositions can be printed by any of the methods described herein, either alone or in combination, to form three dimensional objects.

[0054] Another advantage of additive manufacturing using coreactive compositions may be that the coreactive compositions can be three dimensionally printed at relatively low viscosity. Therefore, relatively large amounts (e.g., high relative weight percents) of additives and/or fillers can be included with the coreactive components while maintaining a printable viscosity. Both the type and/or the amount of additives can be selected or “tuned” to result in desirable chemical and/or physical properties of the printed article. Coreactive compositions can be tuned with the addition of additives and/or fillers for desired mechanical performance (e.g., strength, elasticity, rigidity, sag resistance, etc.), surface features (e.g., hardness, texturing, smoothness, etc.), chemical resistance (e.g., solvent resistance, etc.), thermal resistance (including fire retardancy, etc.) or conductivity, and/or electrical insulation or conductivity. Coreactive compositions can also be tuned with the addition of one or more catalytic/activator/accelerant additives in any of the coreactive components to result in desirable reaction kinetics, such as rate of reaction.

[0055] Table 2 describes additives that can be included with any coreactive compositions, such as those described in Table 1. The additives can be included in, either, or both of, the first and second coreactive components (e.g., either, or both of the Part A/Part B), depending on the desired chemical and/or physical properties of the resulting object. In this case, Table 2 describes specific additives and fillers that may be suitable for ambient reactive extrusion-based three-dimensional printing, however, Table 2 is non-limiting. Therefore, other additives may be included with the coreactive composition(s), such as additives known to those skilled in the coatings, extrusion, and thermoplastic areas.

[0056] Any suitable combination of coreactive composition(s) and optionally additive(s)/filler(s), can be printed by a three-dimensional printing system adapted for mixing and extruding feedstocks. Two or more volumetric metering pumps (e.g., positive displacement pumps, progressive cavity pumps, etc.) may each respectively discharge, in combination or succession, the two coreactive components associated with a coreactive composition (e.g., the first reactive component discharged by the first metering pump and the second coreactive component discharged by the second metering pump into a mixing volume). In some cases, the mixing volume can include mechanical (e.g., driven) mixing features. Upon entering the mixing volume, the first and second coreactive components begin to mix and react, and thereafter, are extruded through an extrusion print nozzle in an at least partially reacted state. Once extruded, the two coreactive components further react and cure, which, as described above, may be under ambient conditions, to form either a thermoset, a thermoplastic material, or combinations thereof.

[0057] III. Multi Axis Additive Manufacturing Device

[0058] The present disclosure provides an additive manufacturing system 100 for 3D printing of objects using coreactive compositions, as seen in FIG. 1. System 100 comprises a print bed 110 and an additive manufacturing device 120 with multiple axes.

[0059] A. Print Bed

[0060] As seen in FIG. 1 and FIG. 13, Print bed 110 may comprise of a print surface 112 and a base 114. Base 114 may be fixed to an anchoring surface 101, such as the ground, a ceiling, a wall, or any other anchoring surface, at a predetermined distance DI from additive manufacturing device 120. Base 114 may comprise a base plate 115 that includes at least one fastener 116 to fix print bed 110 to anchoring surface 101. Coupled to base 114 may be print surface 112 such that a first face 113 of print surface 112 faces up and away from base 114 and base plate 115. First face 113 may be configured to receive a 3D printed object formed from additive manufacturing using a printhead 130 coupled to additive manufacturing device 120, discussed below.

[0061] Print surface 112 may rotate along a first axis Il la and a second axis 111b. First axis Illa may be a rotation that allows print surface 112 to rotate 360 degrees about axis Y. Second axis 111b may allow print surface 112 to tilt toward and away from additive manufacturing device 120 on axis X.

[0062] B. Multiple Axis Device 120

[0063] Additive manufacturing device 120 may be a multiple axis device or multiaxis movable manipulator. Further, device 120 may be a multi-axis robot or other mechanically driven device including a controller that causes the device to carry out programed tasks. Device 120 may comprise a base 122, at least one arm 124 rotatably coupled to base 122, and a printhead 130 coupled to a distal end of the at least one arm 124. Device 120 may be fixed to a surface by base 122. At least one arm 124 may comprise a first arm 124a and a second arm 124b. First arm 124a may extend from base 122 and rotatably couple to second arm 124b. Printhead 130 may be removably and rotatably coupled to the distal end of second arm 124b.

[0064] Device 120 may be any multiple axis device with at least four axes of rotation. As seen in FIG. 1, device 120 may be a multiple axis device with six axes 126a-e of rotation. First arm 124a may rotate 360 degrees about a first axis 126a at interface 121 where first arm 124a couples to base 122. First arm 124a may have a second axis 126b that rotates a joint 123 to adjust the height of first arm 124a. First arm 124a may have a third axis 126c at coupling 125 where a proximal end of second arm 124b is rotatably coupled to first arm 124a. Axis 126b provides flexion and extension of second arm 124b. Second arm 124b may have a fourth axis 126d that rotates a first portion 127 360 degrees. Second arm 124b may have a fifth and sixth axis 126e, 126f that each provide flexion and extension of a second portion 128 of second arm 126b. A person of ordinary skill in the art would understand that the multiple axis device 120 may comprise three or more axes of rotation in a variety of configurations.

[0065] C. Printhead for Multi Axis Additive Manufacturing Device

[0066] Printhead 130 may be rotatably coupled to the distal end of second arm 124b of device 120. Printhead 130 may rotate 360 degrees at axis 131.

[0067] i. 2K Printhead

[0068] As seen in FIG. 2, printhead 130 may be a 2K printhead 230. 2K printhead 230 may print a variety of coreactive compositions, for example the coreactive compositions described above. Printhead 230 may comprise two pumping arrangements 220 that each supply coreactive components used in additive manufacturing. Each coreactive component share a coreactive chemistry with each other. These coreactive components can be combined to form printable coreactive compositions. 2K printhead 230 may be configured to use any of the coreactive components discussed above to print any of the printable compositions described in section II.

[0069] 2K printhead 230 may include two pumping arrangements 220, a mixing arrangement 242, and a print nozzle 260. Printhead 230 may rotatably couple to second arm 126b of multiple axis device 120. Each of the two pumping arrangements 220 may be configured to dispense a coreactive component into mixing arrangement 242.

[0070] The coreactive components may be mixed in mixing arrangement 242 forming a printable composition. The printable composition may be extruded from mixing arrangement 242, through print nozzle 260.

[0071] Each of the two pumping arrangements 220 may include a positive displacement-type pump, such as progressive cavity pump 222. To prevent backflow, progressive cavity pumps 222 can be configured similar to a screw. Due to the design of progressive cavity pumps 222, as the coreactive component is discharged, the flow can only move in the direct of discharge. Additionally, progressive cavity pumps 222 can meter flow to a given volumetric dosage. Alternatively, any cartridge, pen, or other coreactive composition extruder may be used in pumping arrangement 220.

[0072] 2K printhead 230 may be configured to dispense multiple coreactive components of the two pumping arrangements 220 into mixing arrangement 242. The coreactive components may be mixed by static or dynamic mixing in mixing arrangement 242 forming a printable composition. The static and dynamic mixing of the coreactive components of printhead 230 is substantially similar to the static and dynamic mixing of multi-component printhead 330. These mixing methods are discussed in more detail below in reference to multi-component printhead 330.

[0073] After mixing both coreactive components in mixing arrangement 242 creating a printable composition, the printable composition may be extruded from mixing arrangement 242, through print nozzle 260. Print nozzle 260 may deposit the printable composition on first face 113 of print surface 112 such that a 3D object is formed.

[0074] ii. Multiple Component Printhead

[0075] Printhead 130 may be a multi-component printhead 330, as seen in FIG. 3. Multi-component printhead 330 may print a variety of coreactive compositions, for example the coreactive compositions described above, simultaneously and/or sequentially to achieve an object with a variety of physical properties, such as texture, elasticity, hardness, and much more. The versatility of the disclosed multi-component printhead has the benefit of increasing the speed of multi-composition printing due to the lack of need to switch printheads, reducing costs due to one device being needed to print multiple compositions, and allowing the different printed compositions to be combined while in liquid form due to multiple printable compositions being printed in quick succession so they react and cure with one another at the boundary between compositions.

[0076] The printhead 330 of the present application is designed to hold multiple pumping arrangements 320 that supply coreactive components used in additive manufacturing, as seen in FIG. 3. The different coreactive components share a coreactive chemistry with each other. These coreactive components can be combined to form printable coreactive compositions. Each printable coreactive composition is made of a combination of at least two of the coreactive components. Multi-component printhead 330 is configured to use any of the coreactive components discussed above to print any of the printable compositions described in section II.

[0077] Multi-component printhead 330 of the present application may include at least three pumping arrangements 320, a mixing arrangement 342 (FIG. 4), and a print nozzle 360. Printhead 330 may include a top mount 308 that supports each of at least three pumping arrangements 320 and removably couples additive manufacturing device 330 to multiple axis device 120. Each of the at least three pumping arrangements 320 may be configured to dispense a coreactive component into mixing arrangement 342. Additionally, one of the at least three pumping arrangements 320 may include a flush media to dispense through multicomponent printhead 330 in between the printing of different printable compositions. Multicomponent printhead 330 may be configured to dispense multiple coreactive components of the at least three pumping arrangements 320 into mixing arrangement 342. The coreactive components may be mixed in mixing arrangement 342 forming a printable composition. The printable composition may be extruded from mixing arrangement 342, through print nozzle 360. Print nozzle 360 may deposit the printable composition such that a 3D object is formed. Each of the components that comprise multi-component printhead 330 and methods of printing are discussed in more detail below.

[0078] a. Pumping Arrangements

[0079] At least three pumping arrangements 320 can be removably coupled to a diamond mount 340 of multi-component printhead 330 of the present disclosure. Each of the at least three pumping arrangements 320 is fluidly coupled with a source of a respective coreactive component. The respective coreactive component is discharged through a distal end of each of the at least three pumping arrangements 320 into a fluid channel 334. The fluid channel is discussed in greater detail below. As shown in FIG. 5, diamond mount 340 comprises at least three orifices 336 that correspond and receive the distal end of the at least three pumping arrangements 320. Diamond mount 340 may be configured to connect the distal ends of the at least three pumping arrangements 320 with fluid channels 334 such that discharged coreactive components flow from the at least three pumping arrangements 320 into fluid channels 334. Mounting bores 346 may be arranged on diamond mount 340 such that diamond mount 340 is removable coupled to top mount 308 to provide stability to multicomponent printhead 330. The at least three pumping arrangements 320 may be angled relative to axis A, as seen in FIG. 3. Between the support of top mount 308 and the support of diamond mount 340 of the at least three pumping arrangements 320, the at least three pumping arrangements 320 are angled such that the distal end of each of the at least three pumping arrangements points toward axis A.

[0080] Referring to FIG. 3, each of the at least three pumping arrangements 320 includes a positive displacement-type pump, such as progressive cavity pump 322. To prevent backflow, progressive cavity pumps 322 can be configured similar to a screw. Due to the design of progressive cavity pumps 322, as the coreactive component is discharged, the flow can only move in the direct of discharge. Additionally, progressive cavity pumps 322 can meter flow to a given volumetric dosage. Alternatively, any cartridge, pen, or other coreactive composition extruder may be used in pumping arrangement 320.

[0081] As seen in FIGS. 3-5, multi-component printhead 330 may include, a first 322a, second 322b, third 322c, fourth 322d, and fifth 322e progressive cavity pump each containing a different coreactive component. While FIGS. 3-5 demonstrate a configuration of five progressive cavity pumps 322, it is understood that multi-component printhead 330 may be adapted to include four cavity pumps, or, alternatively, three cavity pumps.

[0082] First progressive cavity pump 322a may discharge a first coreactive component in conjunction with second progressive cavity 322b pump that discharges a second coreactive component. Similarly, third progressive cavity pump 322c may discharge a third coreactive component in conjunction with fourth progressive cavity pump 22d that discharges a fourth coreactive component. Fifth progressive cavity pump 322e may discharge a fifth coreactive component in conjunction with at least one of the first, second, third, or fourth progressive cavity pumps 322a-d. Alternatively, any one of progressive cavity pumps 322 may comprise a flush media. To clean out the additive manufacturing device, the flush media may be discharged from progressive cavity pump 322 in between the printing of different printable compositions.

[0083] b. Mixing Arrangement [0084] Referring to FIG. 4, a mixing arrangement 342 for multi-component printhead 330 is provided. Located downstream of pumping arrangements 320 within diamond mount 340, mixing arrangement 342 may comprise a mixing volume 332, at least three fluid channels 334, and a mixer 338. The at least three fluid channels 334 fluidly connect each of progressive cavity pumps 322 to mixing volume 332. The configuration of the at least three fluid channels 334 may be adapted to any arrangement such that the discharged coreactive components flow through the at least three fluid channel 334 into mixing volume 332. Mixing volume 332 may be a cylindrical shape or any other geometry adapted for capturing discharged coreactive components. The geometry of mixing volume 332 may depend on the properties or volume of the discharged coreactive compositions, or available space within diamond mount 340.

[0085] Timing of the coreactive components reaching mixing volume 332 may affect the reaction between coreactive components. Residence timing refers to the time that elapses between one coreactive component entering mixing volume 332 and another coreactive component entering mixing volume 332 to be mixed into a printable composition. The residence timing between one coreactive composition and another may be less than 5 seconds. The progressive cavity pumps 322 containing the coreactive components included in a given printable composition dispense the coreactive components such that the coreactive components are present in mixing volume 332 simultaneously, or, at most, enter into mixing volume 332 from channels 334 within 5 seconds of each other. Once within mixing volume 332, coreactive components may be statically mixed or dynamically mixed together to form a printable composition.

[0086] For dynamic mixing, within mixing volume 332 may be a mixer 338, best seen in FIG. 4, such as an impeller. Impeller 338 may be a screw-like element with threads that dynamically or statically mix coreactive components as the components enter mixing volume 332. For dynamic mixing, impeller 338 may be connected to a motor such that impeller 338 rotates within mixing volume 332.

[0087] The dynamic mixing of the coreactive composition by driven impeller 338 may have certain benefits over static mixing. Generally, mechanical mixing results in more thoroughly mixed coreactive compositions as compared with static mixing (e.g., by the driven nature of impeller 338). In this case, the size of mixing volume 332 may therefore be comparatively smaller than a mixing volume required for static mixing, decreasing the overall size of multi-component printhead 330 (e.g., decreasing the size of mixing volume 332). This relatively smaller size of multi-component printhead 330 results in more stable printing since the volume of retained material (e.g., the amount of material between pumping arrangement 320 and print nozzle 360) within multi-component printhead 330 is lessened, increasing the granularity in pumping rate control.

[0088] Additionally, the rate of reaction between the coreactive components can be more easily controlled by a driven impeller 338. Specifically, the speed that impeller 338 is driven at (e.g., the resulting revolutions per minute (RPM) that impeller 338 spins) can be adjusted to target an overall mixing rate. The RPM simultaneously influences the amount of material extruded from the print nozzle 360. Therefore, RPM can be tuned to simultaneously effect the extent of mixing and extrusion rate, both of which effect the extent and rate of reaction of the coreactive components.

[0089] Furthermore, driven impeller 338 and pumping arrangements 320 can be controlled independently from one another. Therefore, both RPM and pumping rate can be tuned independently, which in combination, may result in any one of a desired extent of reaction of the coreactive components, a targeted reaction rate of the coreactive components, a residence time of material in in the mixing volume 332, and/or a extrusion rate of the coreactive composition from mixing volume 332.

[0090] Additive manufacturing device 100 may hold printable composition within the mixing volume for a period of time. The period of time may be from 0 seconds, 1 seconds, 2 seconds, 3 seconds, to 5 seconds, 6 seconds, 7 seconds, or within any range using any two of the foregoing as endpoints, such as 0-7 seconds, 1-6 seconds, 2-5 seconds, or 3-4 seconds. Holding the printable composition within the mixing volume may ensure that the coreactive components are fully mixed and a homogeneous printable composition is created.

[0091] c. Print Nozzle

[0092] Printable compositions from mixing volume 332 are extruded out a print nozzle 360. Print nozzle 360 is removably coupled to a plug 362 that seals a distal end of mixing volume 332. Plug 362 ensures that the printable composition does not leak out of mixing volume 332. Print nozzle 360 may be a variety of shapes to facilitate the extrusion of printable compositions.

[0093] d. Flush Media

[0094] Once a printable composition has been extruded from nozzle 360 to form a 3D object, the user may want to change the type of printable composition extruded from additive manufacturing device 360. In order to ensure that mixing arrangement 342 is free of previously printed printable composition, a flush media may be extruded by one of the at least three pumping arrangements 320. The flush media may be a commercially available non-reactive media configured to clear printable compositions from mixing arrangement 342. The flush media may be a flowable, non-reactive composition, such as, but not limited to, a hydrogel.

[0095] e. Method of Printing a 3D Object Using Multi¬

Component Printhead

[0096] Referring to FIG. 6, a method of additive manufacturing is shown for printing a 3D object using the printhead 330. Method 600 comprises a combining step 602, an extruding step 604, a flush step 606, a combining step 608, and an extruding step 610. In combining step 602, a first coreactive component and a second coreactive component are combined in a mixing arrangement. Prior to combination, the first and second coreactive components may be held in corresponding pumping arrangements 320 of printhead 330. To combine the first and second coreactive components, the components may be added to mixing arrangement 342 and mixed with impeller 338. Once combined, the first and second coreactive components may react to form a coreactive composition, or a first printable composition. The mixing parameters such as time spent mixing, mixing speed, mixing device, temperature, and/or pressure may vary depending on operating parameters or desired product parameters such as the amount and type of coreactive components used, the volume of components in the mixture, desired properties of the printable composition, desired properties of the printed object, and any combination of the foregoing. The first printable composition may be any of the printable compositions mentioned in section II above.

[0097] Extruding step 604 comprises extruding the first printable composition from the mixing arrangement through a print nozzle onto a printing surface to form a 3D object. The printing surface may be a printing bed or any other material, such as first face 113 of print surface 112 as seen in FIG. 1. The speed of extruding the first printable composition from the mixing arrangement may vary depending on the properties of the printable composition.

[0098] To continue with printing a second printable composition, flushing step 606 comprises flushing the mixing arrangement with a non-coreactive component. The non- coreactive component may be any commercially available flush media. Flush media may be held in a pumping arrangement, similar to the first and second coreactive components. Flushing step 606 may remove residual printable composition, or previous coreactive components from the mixing arrangement so that further printable compositions are not contaminated with previous coreactive components or printable compositions.

[0099] In combining step 608, a third coreactive component and a fourth coreactive component are combined in a mixing arrangement. The coreactive components may be any of the coreactive components mentioned in section II above. Prior to combination, the third and fourth coreactive components may be held in corresponding pumping arrangements 320 of printhead 330. To combine the third and fourth coreactive components, the components may be added to mixing arrangement 342 and mixed with impeller 338. Once combined, the third and fourth coreactive components may react to form a second printable composition. Similar to the first printable composition, the mixing parameters may vary depending on the properties of the coreactive components and the second printable composition. The second printable composition may also be any of the printable compositions mentioned in section II above.

[0100] Extruding step 610 comprises extruding the second printable composition from mixing arrangement 342, through print nozzle 360, and onto first face 113 of print surface 112. The speed of extruding the second printable composition from mixing arrangement 342 may vary depending on the properties of the printable composition. The second printable composition may be extruded onto the first printable composition that has already been deposited such that the first printable composition and second printable composition become one 3D printed object. The speed of which the second printable composition is deposited onto the first printable composition may be faster than the speed at which the first printable composition can fully cure. If the first printable composition is not fully cured, the first printable composition and the second printable composition may react at the boundary between the first printable composition and the second printable composition to create the one 3D printed object.

[0101] To continue printing printable compositions, method 600 may optionally have a second flushing step 612. Flushing step 612 may comprise flushing mixing arrangement 342 with the flush media, similar to flushing step 606. Further, method 600 may be optionally repeated to fully complete a desired 3D printed object. A 3D objected printed using method 600 may include multiple printable compositions printed from printhead 330 in quick succession. By flushing mixing arrangement 342 in between printing different printable compositions, method 600 may print different printable compositions that are free from contaminants from each printable composition. [0102] A 3D printed object created using method 600 may be made of multiple printable compositions. Due to the speed of printing multiple printable compositions using method 600, the final 3D printed object may be made of printable compositions that have reacted with each other and formed one multi-printable composition 3D object.

[0103] The present disclosure provides a second method of printing using printhead 330.

[0104] Referring to FIG. 7, a method of additive manufacturing is shown for printing a 3D object using printhead 330. Method 700 comprises a combining step 702, an extruding step 704, a combining step 706, and an extruding step 708. In combining step 702, a first coreactive component and a second coreactive component are combined in mixing arrangement 342. The coreactive components may be any of the coreactive components mentioned in section II above. Prior to combination, the first and second coreactive components may be held in corresponding pumping arrangements 320 of printhead 330. To combine the first and second coreactive components, the components may be added to mixing arrangement 342 and mixed with impeller 338. Once combined, the first and second coreactive components may react to form a first printable composition. The mixing parameters such as time spent mixing, mixing speed, mixing device, temperature, and/or pressure may vary depending on operating parameters or desired product parameters such as the amount and type of coreactive components used, the volume of components in the mixture, desired properties of the printable composition, desired properties of the printed object, and any combination of the foregoing. The first printable composition may be any of the printable compositions mentioned in section II above.

[0105] Extruding step 704 comprises extruding the first printable composition from mixing arrangement 342, through print nozzle 360, onto first surface 113 of print surface 112 to form a 3D object. Printing surface 112 may be a printing bed or any other material. The speed of extruding the first printable composition from the mixing arrangement may vary depending on the properties of the printable composition.

[0106] In combining step 706, a third coreactive component is combined with the first coreactive component in the mixing arrangement. The coreactive components may be any of the coreactive components mentioned in section II above. Prior to combination, the third coreactive component may be held in pumping arrangements 320 of an printhead 330. Each of pumping arrangements 320 of printhead 330 may contain a coreactive component. The first coreactive component may react with each of the other coreactive components to form different printable compositions. That is to say, each coreactive component reacts with the first coreactive component to form a respective printable composition. There may be a first, second, third, fourth, and fifth coreactive component held in a corresponding pumping arrangement.

[0107] Referring back to step 706, to combine the first and third coreactive components, the components may be added to a mixing arrangement and mixed with impeller 338. Once combined, the first and third coreactive components may react to form a second printable composition. Similar to the first printable composition, the mixing parameters may vary depending on the properties of the coreactive components and the second printable composition. The second printable composition may also be any of the printable compositions mentioned in section II above.

[0108] Extruding step 708 comprises extruding the second printable composition from mixing arrangement 342 through print nozzle 360 onto first surface 113 of printing surface 112 to form a 3D object. Printing surface 112 may be a printing bed or any other material. The speed of extruding the first printable composition from mixing arrangement 342 may vary depending on the properties of the printable composition.

[0109] The second printable composition may be extruded onto the first printable composition that has already been deposited such that the first printable composition and second printable composition become one 3D printed object. The speed of which the second printable composition is deposited onto the first printable composition may be faster than the first printable composition can fully cure. If the first printable composition is not fully cured, the first printable composition and the second printable composition may react at the boundary between the first printable composition and the second printable composition to create the one 3D printed object.

[0110] Method 700 may optionally include a flushing step 710 that comprises flushing the mixing arrangement with a non-coreactive component. The non-coreactive component may be a flush media previously described. Flushing step 710 may remove any residual printable composition, or previously used coreactive components from the mixing arrangement so that further printable compositions are not contaminated with previous coreactive components or printable compositions. Step 710 is not required but may be included if desired. Additionally, method 700 may optionally be repeated to form a multi- printable-composition 3D object.

[0111] IV. Printing a 3D Object [0112] The multi-axis additive manufacturing device 120 and rotating print bed 110 of the present disclosure allow for a variety of different 3D objects to be printed. To achieve different thicknesses of printed material when forming 3D object 10, the flow rate of the coreactive composition and the speed of the motion of the print arm may be varied. The flow rate and speed of motion of the print arm may be kept proportional to each other during printing to form print lines of equal thickness. To vary the thickness of a print line, the flow rate and speed of motion of the print arm may be varied independent of one another.

[0113] A. Support Structures and Orientation of the 3D Object During

Printing

[0114] By rotating and tilting print bed 110 and multi-axis additive manufacturing device 120, a 3D object may be printed without using support structures. As seen in FIG. 8A, when printing a 3D object 10 using a fixed print bed 20 and/or a 3D printing device that does not have more than three axes of movement 30, 3D object 10 may be printed with a support structure 16. As device 30 prints object 10 from a bottom portion 1 la to a top portion 1 lb, overhang 14 will be pulled down toward ground 101 due to gravity. To prevent sag and droop of overhang 14, device 30 may print a support structure 16. Any sag or droop in the portion of printed object 10 that forms overhang 14 may alter the shape of printed object 10.

[0115] As shown in FIG. 8B, multi-axis additive manufacturing device 120 and rotating print bed 110 of the present application may print 3D object without support structures by rotating/tilting print bed 110 and rotating printhead 130 of the multi axis additive manufacturing device 120 to print at angles that avoid allowing the extruded coreactive composition from sagging. A method of printing a 3D object with an overhang without support structures is shown progressive series of figures FIGS. 9A-E.

[0116] To achieve printed 3D objects without support structures, the print bed may rotate and tilt such that the portion of the 3D object 10 being printed is always parallel to ground 101 where base 114 of print bed 110 may be fixed. Referring to FIGS. 9B-9E, a 3D printed object 10 with a first portion 90 and a second portion 92 comprising an overhanging portion 14 can be seen. Line X depicts the layer of object 10 being printed in each of the progressive figures. In FIGS. 9B-C, first portion 90 may be printed along line X. First portion 90 is parallel to print surface 112 of print bed 110 and ground 101 that base 114 of print bed 110 may be fixed to. The additive manufacturing system 100 may extrude coreactive composition from printhead 130 of device 120 without rotating or tilting print surface 112 of print bed 110. The print speed of the coreactive composition may be reduced to allow for each layer to cure before printing the next layer to avoid sagging. Printing too fast between layers may cause partially cured layers to sag or buckle under the weight of a newly printed layer.

[0117] Second portion 92 of object 10 includes an overhang 14. When printing second portion 92 of object 10, to avoid portion 92 from drooping/sagging, additive manufacturing system 100 may tilt printing surface 112 of print bed 110 to orient printed object 10 such that second portion 92 is parallel to ground 101 base 114 of print bed 110 may be attached to. As shown in FIGS. 9D-E, as printing line X progresses to second portion 92, printing surface 112 of print bed 110 tilts at an angle relative to ground 101 to avoid the use of support structures.

[0118] B. Impossible Geometries

[0119] Printing a 3D object using a device with three or less axes and/or a fixed print bed may result in a reduced range of motion and limitation of potential geometries of 3D shapes that can be printed. Referring to FIGS. 10A-B, two 3D objects 60 and 70 are shown. It may be desirable to print an interface surface 50 that lies between object 60 and object 70. Device 30 has three or fewer axis of rotation. As device 30 attempts to print along interface surface 50, due to the physical dimensions of the printhead of device 30 and lack of ability to rotate, there is a portion of surface 50 that device 30 cannot reach without running into object 60 or object 70. Device 30 may attempt to print along a bottom portion 51 of interface surface 50. Because device 30 has three axes or less, a side surface 31 of device 30 may be at risk of impacting object 70 along edge 71 when device 30 attempts to print along the bottom portion 51 of interface 50. Due to the impact of edge 71 by surface 31, device 30 may not be able to print along interface surface 50.

[0120] As seen in FIG. 10B, the additive manufacturing device 120 of the present disclosure may rotate on a variety of axes, orienting printhead 130 in various positions. When printing along interface 50 between object 60 and object 70, device 120 may adjust the angle of printhead 130 using the multiple axes of rotation of device 120 to allow printing along surface 50 without running into object 60 or object 70. Because of the freedom of rotation multiple axes, device 120 may have an increased number of accessible geometries over devices with fewer axes of rotation.

[0121] C. Rotation of the Device v. Rotation of the Print Bed

[0122] Additive manufacturing system 100 may involve controlling multiple axes of additive manufacturing device 120 and print bed 110 simultaneously. The coordination of all axes of system 100 may increase the complexity of printing in a repeated motion, such as printing repeated vertically displaced concentric circles to form a cylindrical 3D printed object. A first method of printing such a cylinder object 10 may comprise printing along print motion line 17 in vertically displaced concentric circles by manipulating device 120 using multiple axes 126a-f. A second method of the present disclosure to print object 10 may comprise fixing printhead 130 in place and rotating print bed 110 along axis Il la such that print surface 112 rotates 360 degrees underneath printhead 130. As each circular layer of object 10 is printed, device 120 may use one axis to move print nozzle 160 of printhead 130 vertically upward to start the next circular layer for printing. With a reduction of axes to coordinate during printing, the second method of printing may complete the printing of object 10 faster than the first method described.

[0123] D. Fixed v. Conformal Printing

[0124] Traditional fixed printing is a method of 3D printing that comprises depositing a printable composition layer by layer to form a 3D printed object. As seen in FIG. 12A, by using fixed printing, a curvature 18 of object 10 may be printed layer by layer. Each layer 19 may create a textured demarcation line between the next layer due to each layer being printed separately. Additive manufacturing system 100 may print 3D objects using fixed printing. [0125] Conformal printing, as seen in FIG. 12B, is a method of 3D printing that comprises moving a printhead along curvatures of the 3D printed object while depositing printable composition, as opposed to printing in layers. By moving along the curvatures of an object, conformal printing may reduce the demarcation lines due to fewer printed layers. As seen in FIG. 12B, additive manufacturing system 100 of the present disclosure may print 3D objects using conformal printing by manipulating the multiple axes 126 of device 120 to move printhead 130 along curvature 18 of 3D printed object 10.

[0126] IV. Software for Printing a 3D Object

[0127] As shown in Figure 14, a computer system 1400 may comprise one or more processors 1410 and computer-executable instructions stored on computer-storage media 1420. When executed, the computer-executable instructions (also referred to as “3D printing software 1430”) may configure the computer system 1400 to control the additive manufacturing system 100. The computer-executable instructions may be capable of controlling any electronic feature of the additive manufacturing system.

[0128] The computer-executable instructions may control actuators, such as motors, that move and position the arms 124 of the additive manufacturing system 100. For example, as shown in Figure 1, motors may be integrated with each of the axes 126a-e. The computerexecutable instructions may cause the motors to acuate the arms 124 to desired positions and at desired speeds. Similarly, the computer-executable instructions may cause one or more actuators connected to the print bed 110 to rotate, tilt, or otherwise move the print surface 112. Additionally, the computer-executable instructions may control the pumping arrangements 220 and mixing arrangement 242 within the additive manufacturing system 100.

[0129] The 3D printing software application 1430 may comprise various modules that cause the additive manufacturing system 100 to print the desired 3D object 10. As used herein, a “module” comprises computer executable code and/or computer hardware that performs a particular function. One of skill in the art will appreciate that the distinction between different modules is at least in part arbitrary and that modules may be otherwise combined and divided and still remain within the scope of the present disclosure. As such, the description of a component as being a “module” is provided only for the sake of clarity and explanation and should not be interpreted to indicate that any particular structure of computer executable code and/or computer hardware is required, unless expressly stated otherwise.

[0130] A motor control module 1440 may be configured to control various actuators within the additive manufacturing system 100. The motor control module 1440 may communicate directly to one or more actuators and/or to one or more motor controllers. The motor control module 1440 may utilize public and private Application Programming Interfaces (APIs) associated with the motor controllers. Further, the motor control module 1440 may be capable of operating with a variety of different types and models of actuators such that the additive manufacturing system 100 may be updated or retrofitted with different motors that the motor control module 1440 can still control.

[0131] A 3D object module 1450 may be configured to receive and/or analyze an instruction file for creating the 3D object 10. The instruction file may comprise a Computer- Aided Design (CAD) file, a g-code file, or any other file capable of containing information necessary for printing the 3D object 10. The 3D object module 1450 may be configured to create or adjust one or more toolpaths that are used to print the 3D object 10. Additionally, the one or more toolpaths may be created in conjunction with programmed movements of the print surface 112. For example, the 3D object module 1450 may be configured to create or adjust toolpaths and print surface 112 movements for overhangs, tapered surfaces, interfaces between different types of coreactive compositions, and other similar areas in the 3D object 10.

[0132] A chemical component module 1460 may be configured to receive and/or analyze information relating to the coreactive components and fillers that are to be used and/or available to print the 3D object 10. The chemical component module 1460 may automatically or manually receive information about each coreactive component that is connected to a pumping arrangement 220. For example, a user may manually type in the information indicating which coreactive component was connected to which pumping arrangement 220. Additionally or alternatively, each container of coreactive component may be associated with an RFID chip, integrated memory chip, or some other electronic device that is configured to automatically, electronically share the information indicating which coreactive component was connected to which pumping arrangement 220.

[0133] The chemical component module 1460 may also have access to a database, or lookup table, stored within the computer-storage media 1420. The database may comprise information describing the physical and chemical characteristics of each coreactive component, coreactive composition, and/or additive/filler. For example, each of the components described above in Table 1 and Table 2 may be more fully characterized by experimentation to determine the resulting viscosity, curing speed, and other characteristics based upon ratios of the different components, the temperature at the time of mixing, the speed of mixing, the humidity at the time of mixing, and/or various other physical characteristics and chemical characteristics of each coreactive component, coreactive composition, and/or additive/filler.

[0134] Using the motor control module 1440, the 3D object module 1450, and the chemical component module 1460, the 3D printing software 1430 can control the additive manufacturing system 100. In particular, the 3D printing software 1430 can automatically and dynamically adjust the printing of the 3D object 10 based upon the structure of the 3D object 100 and the characteristics of the coreactive composition and/or additives/fillers. For example, the 3D printing software 1430 may receive a 3D object 10 that comprises an overhang. The 3D object module 1450 may identify the path that the nozzle will travel while extruding the various layers that will construct the overhang. The chemical component module 1460 may also identify the viscosity and curing speed of the coreactive composition that will be used to print the overhang. For instance, the chemical component module 1460 may provide viscosity information to the 3D object module 1450. The 3D object module 1350 may determine an extrusion speed threshold that the nozzle cannot exceed without risking the overhang sagging. Using this information, the motor control module 1440 may cause the arms to move at a particular speed and the pumping arrangements 220 to pump the coreactive components at a particular speed while printing the overhang portion of the 3D object 10.

[0135] Additionally or alternatively, the motor control module 1440 may cause the print surface 112 to tilt in a direction that reduces the angle of the overhang relative to the direction of gravity. The motor control module 1440 may then cause the nozzle and/or print surface 112 to move at a speed that accounts for both the viscosity of the coreactive composition and the cure time of the coreactive composition. For example, the nozzle and/or print surface 112 may move at a speed that prevents the viscosity of the coreactive composition from sagging and also allows the coreactive composition to at least partially cure to a level that will allow the overhang to maintain its correct shape as defined by the instruction file for creating the 3D object 10.

[0136] Further, the methods may be practiced by a computer system including one or more processors and computer-readable media such as computer memory. In particular, the computer memory may store computer-executable instructions that when executed by one or more processors cause various functions to be performed, such as the acts recited in the embodiments.

[0137] Computing system functionality can be enhanced by a computing systems’ ability to be interconnected to other computing systems via network connections. Network connections may include, but are not limited to, connections via wired or wireless Ethernet, cellular connections, or even computer to computer connections through serial, parallel, USB, or other connections. The connections allow a computing system to access services at other computing systems and to quickly and efficiently receive application data from other computing systems.

[0138] Interconnection of computing systems has facilitated distributed computing systems, such as so-called “cloud” computing systems. In this description, “cloud computing” may be systems or resources for enabling ubiquitous, convenient, on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, services, etc.) that can be provisioned and released with reduced management effort or service provider interaction. A cloud model can be composed of various characteristics (e.g., on-demand self-service, broad network access, resource pooling, rapid elasticity, measured service, etc.), service models (e.g., Software as a Service (“SaaS”), Platform as a Service (“PaaS”), Infrastructure as a Service (“laaS”), and deployment models (e.g., private cloud, community cloud, public cloud, hybrid cloud, etc.).

[0139] Cloud and remote based service applications are prevalent. Such applications are hosted on public and private remote systems such as clouds and usually offer a set of web based services for communicating back and forth with clients.

[0140] Many computers are intended to be used by direct user interaction with the computer. As such, computers have input hardware and software user interfaces to facilitate user interaction. For example, a modern general purpose computer may include a keyboard, mouse, touchpad, camera, etc. for allowing a user to input data into the computer. In addition, various software user interfaces may be available.

[0141] Examples of software user interfaces include graphical user interfaces, text command line based user interface, function key or hot key user interfaces, and the like. [0142] Described computer systems may comprise or utilize a special purpose or general-purpose computer including computer hardware, as discussed in greater detail below. Described computer systems also include physical and other computer-readable media for carrying or storing computer-executable instructions and/or data structures. Such computer- readable media can be any available media that can be accessed by a general purpose or special purpose computer system. Computer-readable media that store computer-executable instructions are physical storage media. Computer-readable media that carry computerexecutable instructions are transmission media. Thus, by way of example, and not limitation, embodiments of the invention can comprise at least two distinctly different kinds of computer-readable media: physical computer-readable storage media and transmission computer-readable media.

[0143] Physical computer-readable storage media includes RAM, ROM, EEPROM, CD-ROM or other optical disk storage (such as CDs, DVDs, etc.), magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer.

[0144] A “network” is defined as one or more data links that enable the transport of electronic data between computer systems and/or modules and/or other electronic devices. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a computer, the computer properly views the connection as a transmission medium. Transmissions media can include a network and/or data links which can be used to carry program code in the form of computer-executable instructions or data structures, and which can be accessed by a general purpose or special purpose computer. Combinations of the above are also included within the scope of computer-readable media.

[0145] Further, upon reaching various computer system components, program code means in the form of computer-executable instructions or data structures can be transferred automatically from transmission computer-readable media to physical computer-readable storage media (or vice versa). For example, computer-executable instructions or data structures received over a network or data link can be buffered in RAM within a network interface module (e.g., a “NIC"), and then eventually transferred to computer system RAM and/or to less volatile computer-readable physical storage media at a computer system. Thus, computer-readable physical storage media can be included in computer system components that also (or even primarily) utilize transmission media.

[0146] Computer-executable instructions comprise, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. The computerexecutable instructions may be, for example, binaries, intermediate format instructions such as assembly language, or even source code. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the described features or acts described above. Rather, the described features and acts are disclosed as example forms of implementing the claims.

[0147] Those skilled in the art will appreciate that the computer-executable instructions may be executed in network computing environments with many types of computer system configurations, including, personal computers, desktop computers, laptop computers, message processors, hand-held devices, multi-processor systems, microprocessorbased or programmable consumer electronics, network PCs, minicomputers, mainframe computers, mobile telephones, PDAs, pagers, routers, switches, and the like. The computerexecutable instructions may also be executed in distributed system environments where local and remote computer systems, which are linked (either by hardwired data links, wireless data links, or by a combination of hardwired and wireless data links) through a network, both perform tasks. In a distributed system environment, program modules may be located in both local and remote memory storage devices.

[0148] Alternatively, or in addition, the functionality described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that can be used include Field-programmable Gate Arrays (FPGAs), Program-specific Integrated Circuits (ASICs), Program-specific Standard Products (ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc.

EXAMPLES

[0149] Aspects of the present disclosure are further illustrated by reference to the following examples. It will be apparent to those skilled in the art that many modifications, both to materials, and methods, may be practiced without departing from the scope of the disclosure.

Examples of Printing Methods Using the Multicomponent Printhead

Example 1 - In-Line Compositional Changes with ARE 3D-Printing

[0150] Each of the five progressive pumps were loaded with distinct formulations to allow for two unique thermoset compositions to be printed into a single 3D-printed part. To print the first composition, pump 1 was loaded with a first amine formulation (Formulation A) and pump 2 was loaded with a first isocyanate formulation (Formulation E). The first segment of the part was printed by metering formulations from pumps 1 and 2 in a fixed volumetric ratio through a mixer to produce a first thermosetting composition. The first composition was deposited on the print bed in a predefined toolpath until the part segment was completed. The printhead was then moved to a defined purge or flush location. A purge compound, loaded in pump 3, was then metered through the mixer to remove all the first composition from the print head. Once flushing was complete, the printhead returned to an area on the print bed where the second segment of the part would be printed. The second segment was printed by metering a second amine formulation (Formulation B) from pump 4 and a second isocyanate formulation (Formulation F) from pump 5 in a fixed volumetric ratio through a mixer to produce a second thermosetting composition. The second composition was deposited on the print bed in a predefined toolpath as to complete the final part in conjunction with the first segment. The final multi-composition part was allowed to cure at 71 °C for 48 hours.

Example 2 - On-Demand Material Property Modulation with ARE 3D-Printing

[0151] Each of the five progressive pumps were loaded with distinct formulations to allow for on-demand modulation of material properties in a 3D-printed part. Pump 1 was loaded with isocyanate formulation E and pumps 2-5 were loaded with amine formulations A-D, respectively. At the start of the print, the first segment was printed by metering formulations A-D with respect to formulation E through a mixer in a defined volumetric ratio to produce a first thermosetting composition with known material properties. At the conclusion of the first segment, a second segment was printed by varying the ratio at which formulations A-D were metered with respect to formulation E; thereby creating a second thermosetting composition with distinct material properties from the first. This process was repeated two more times to create third and fourth thermosetting compositions for third and fourth segments of the printed part. This resulted in a single 3D-printed article with four segments, each having distinct material properties. The final part was allowed to cure at 71 °C for 48 hours.

Example 3 -Printing a 3D Ob ject Using the Multi Axis Additive Device

[0152] Each of the five progressive pumps were loaded with distinct formulations to allow for two unique thermoset compositions to be printed into a single 3D-printed part. To print the first composition, pump 1 was loaded with a first amine formulation (Formulation A) and pump 2 was loaded with a first isocyanate formulation (Formulation E). The print bed was oriented in a first configuration and the first composition was deposited on the print bed in a predefined toolpath until the part segment was completed under different printing conditions. The print bed was reorientated into a second configuration that was non-parallel to the first position. The first composition was deposited on the bed with a pre-determined toolpath until the part segment was completed. Once flushing was complete, the printhead returned to an area on the print bed where the second segment of the part would be printed. The print head angle was changed. To print the second composition, pump 1 was loaded with a second amine formulation (Formulation B) and pump 2 was loaded with a first isocyanate formulation (Formulation D). The print head angle was rotated to allow touching access to part and the second composition was deposited on the print bed in a predefined toolpath until the part segment was completed under different printing conditions. A multi-material component with an over-hang allowed to cure at 71 °C for 48 hours.

Claims

CLAIMS What is claimed is:

1. A method of printing a 3D article comprising: combining a first coreactive component and second coreactive component in a mixing arrangement of a printhead coupled to a multi-axis movable manipulator, the first coreactive component and the second coreactive component reacting to form a first printable composition; moving the printhead while extruding the first printable composition to print a first portion of a 3D printed article onto a print bed with the print bed disposed in a first orientation, wherein the first portion of the 3D printed article is printed along a first axis; moving the print bed to a second orientation which is non-parallel to the first orientation; and moving the printhead while extruding the first printable composition to print a second portion of the 3D printed article onto the first portion of the 3D printed article, wherein the second portion of the 3D printed article is printed along a second axis, the second axis being non-parallel with the first axis.

2. The method of claim 1, wherein the mixing arrangement includes a mechanical mixer.

3. The method of any one of claims 1-3 further comprising combining a third coreactive component and a fourth coreactive component in the mixing arrangement, the third coreactive component and the fourth coreactive component reacting to form a second printable composition.

4. The method of claim 3, further comprising moving the print bed to a third orientation which is non-parallel to at least one of the first orientation and the second orientation.

5. The method of claim 4 further comprising moving the printhead while extruding the second printable composition to print a third portion of the 3D printed article onto one of the first portion or the second portion of the 3D printed article, wherein the third portion of the 3D printed article is printed along a third axis with the third axis non-parallel with either the first axis or the second axis.

6. The method of any one of claims 1-5, wherein moving the print bed to the first orientation orients the first axis perpendicular to a ground surface and moving the print bed to the second orientation orients the second axis at a non-parallel angle to the ground surface.

7. The method of claim 3, wherein the first printable composition and the second printable composition each comprise: a filler in an amount from 1 wt. % to 20 wt. %, based on the total weight of the composition; and a solvent in an amount of less than 5 wt. %, based on the total weight of the composition; wherein the first printable composition and the second printable composition each comprise a thermosetting composition and are characterized by a viscosity from 5,000 cP to 5,000,000 cP, measured using a rheometer with a gap from 1 mm to 2 mm, a shear rate of 0.1 at 0.1 s ¹ at a temperature of 25° C.

8. The method of any one of claims 1-7, wherein the printhead is moved at a speed that is determined, at least in part, based upon physical characteristics or chemical characteristics of the first printable composition.

9. An additive manufacturing system for printing 3D objects comprising: a multi-axis movable manipulator comprising: a base fixed to a surface; a first arm rotatably coupled to the base; a second arm rotatably coupled at a proximal end of the second arm to the first arm; and a printhead rotatably coupled to a distal end of the second arm; wherein the first and second arm are each configured to rotate about different axes of rotation such that the multi-axis movable manipulator may move along at least four axes of rotation; and a tiltable and rotatable print bed, the print bed comprising: a base fixed to an anchoring surface; a print surface coupled to the base; wherein the print surface is configured to tilt between a horizontal position and a non-horizontal position and also rotate about an axis.

10. The additive manufacturing system of claim 9, wherein the multi-axis additive manufacturing device is spaced a predetermined distance away from the tiltable and rotatable print bed such that the printhead may be oriented to interact with the print surface.

11. The additive manufacturing system of any one of claims 9-10, wherein the printhead comprises a 2K printhead, the 2K printhead comprising: two pumping arrangements, each of the two pumping arrangements configured to dispense a respective printable component; a mixing arrangement fluidly coupled to the two pumping arrangements, the mixing arrangement comprising: a mixing volume: two fluid channels, wherein each of the two fluid channels is fluidly coupled with one of the two pumping arrangements, and the respective printable component dispensed by each of the two pumping arrangements flows into the mixing volume through the fluid channel fluidly coupled to the pumping arrangement; and a mechanical mixer positioned within the mixing volume, the mixer configured to mechanically mix the printable components dispensed from the two pumping arrangements; and a print nozzle fluidly coupled to the mixing arrangement, the print nozzle configured to extrude the printable components during an additive manufacturing process.

12. The additive manufacturing system of claim 11, wherein each of the two pumping arrangements comprise a progressive cavity pump, each one of the progressive cavity pumps fluidly coupled with a source of the respective printable component.

13. The additive manufacturing system of claim 9, wherein the printhead comprises a multi-component printhead, the multicomponent printhead comprising: at least three pumping arrangements, each of the at least three pumping arrangements configured to dispense a respective printable component; a mixing arrangement fluidly coupled to each of the at least three pumping arrangements, the mixing arrangement comprising: a mixing volume; at least three fluid channels, wherein each one of the at least three fluid channels is fluidly coupled with one of the at least three pumping arrangements, and the respective printable component dispensed by each of the at least three pumping arrangements flows into the mixing volume through the fluid channel fluidly coupled to the pumping arrangement; and a mechanical mixer positioned within the mixing volume, the mixer configured to mechanically mix the printable components dispensed from the at least three pumping arrangements; and a print nozzle fluidly coupled to the mixing arrangement, the print nozzle configured to extrude the printable components during an additive manufacturing process.

14. The additive manufacturing system of claim 13, wherein at least two of the printable components dispensed by at least two of the at least three pumping arrangements comprise coreactive components that react under ambient conditions during the additive manufacturing process.

15. The additive manufacturing system of either claim 13 or claim 14, wherein each of the at least three pumping arrangements dispenses a different printable component.

16. The additive manufacturing system of any one of claims 9-15, wherein the at least three pumping arrangements comprise five pumping arrangements.

17. The additive manufacturing system of either claim 15 or claim 16, wherein each of the different printable components comprise a first coreactive component, a second coreactive component, a third coreactive component, and a fourth coreactive component, and the first coreactive component and the second coreactive component react to form a first coreactive composition, and the third reactive component and the fourth reactive component react to form a second coreactive composition different than the first coreactive composition.

18. The additive manufacturing system of claim 17, wherein a first pumping arrangement discharges the first coreactive component in conjunction with the second pumping arrangement that discharges the second coreactive component.

19. The additive manufacturing system of any one of claims 17-18, wherein a third pumping arrangement discharges the third coreactive component in conjunction with a fourth pumping arrangement discharging the fourth coreactive component.

20. The additive manufacturing system of any one of claims 9-19, wherein one of the printable components discharged by the at least three pumping arrangements comprises a flush media.

21. The additive manufacturing system of claim 20, wherein the flush media is discharged into the mixing arrangement and discharges residual one or more printable components present in the mixing arrangement.

22. The additive manufacturing system of any one of claims 9-21, wherein the tiltable and rotatable print bed is configured to orient the print surface such that printable compositions extruded from the printhead onto the print surface are at least partially cured parallel to the anchoring surface.

23. The additive manufacturing system of any one of claims 9-22, further comprising: one or more processors; and one or more computer-readable media having stored thereon executable instructions that when executed by the one or more processors configure the additive manufacturing system to: generate commands to move the printhead at a speed that is determined, at least in part, based upon physical characteristics or chemical characteristics of the printable components.

24. The method of any one of claims 1-8, carried out using the additive manufacturing system of any one of claims 9-23.