GB2588192A - A 3D printing device - Google Patents

Abstract

A 3D printing device 100 with at least six independently controllable motorised cable winch units 1-3, 5-7 fixed to at least three structural support legs 23-25. Each winch unit has a motorised mechanism that generates movement of the unit along its support leg. Each winch unit has a winch cable 11-13, 15-17 and associated spooling system, a cable runner and associated operation mechanism with a sensory device for measuring winch cable extension length. Each cable controls the moment of a single material dispensing head 9 via a dispensing head mounting cradle or fixing features on the outer shell of the material dispensing head. A controller processes data for operation of the cable winch units derived from a G-CODE or AMF file. The arrangement is intended to reduce the need for a bulky print chassis that must exceed the dimensions of the printing envelope.

Description

Field of the Invention

The present invention relates to a three-dimensional (3D) Printing Device for producing physical 3D objects by way of incremental addition of material, working from the bottom of a print in successive layers upward. The invention is applicable to the field of 3D Printing.

Summary of the Prior Art

3D Printing relates to the process of producing three-dimensional objects by depositing material in incremental layers and is often rcfcrrcd to as Additive Manufacturing (AM). Before commencement of manufacture, Computer Aided Design (CAD) software is used in the first instance to produce a 3D model of the desired object. The digital representation of the object is then processed through device specific 3D Printing software to produce a digital instruction of operation for the 3D Printer. This is sometimes referred to as an Additive Manufacturing File (AMF) or 0-CODE. The 0-CODE or AMF provides the 3D Printer with the necessary commands to produce each successive layer of material to produce the desired article of manufacture.

Various methods of 3D Printing are known; one such example is described in US Patent No US5121329 -"Apparatus and method for creating three-dimensional objects". This describes the process known as Filament Deposition Manufacturing (FDM) which incorporates a heated manoeuvrable dispensing head to extrude material, typically thermoplastics, in layers onto a base member through controlled movements of die dispensing head.

Previous arrangements of 3D printers have been described either literature or marketed products that enable delta movement of the dispensing head along a solid structural apparatus via the use of servo motors and linear guides. This arrangement requires at least three orthogonal structural linear guides to manoeuvre the dispensing head for the three desired axis of printing freedom.

One problem with this arrangement is the need for a bulky print chassis that must exceed the length, width and depth of the printing envelope, which can become cumbersome for manufacturing larger articles and creates a restriction to the size of practical print envelope, as a larger print volume necessitates a larger 3D printer. This is especially true in the context of construction 3D Printing (C3DP) where the desired object of manufacture may exceed fifty cubic meters (50m3). The logistical burden and financial cost of manufacturing and erecting devices sizeable enough to produce such articles may nullify the inherent benefits of 3D printing in reducing the cost and time of producing 3D articles.

To minimise this constraint the linear guides may be relinquished in favour of a winch cable arrangement. Ceiling mounted cable robots are known, an example of such systems can be found in the British patent No GB2566032 -"Cable Robot and Method of Large Scale Production of Articles". These systems are limited by the requirement of mounting to a ceiling of some description, which may restrict printing activities to manufacturing articles in segments to be assembled at a final location, or to manufacturing and assembling a ceiling structure at point of desired print location in order to mount the robot.

To overcome the issue described above a winch cable arrangement can be coupled with a solid supporting structure to actuate off of to achieve the desired movement of the dispensing head. Apparatus of this description are known and has been described in the US Patent 2009/0066100 A I -"Apparatus and Method Associated with Cable Robot System". in this system cable winch units are mounted on the ground and the winch cables are fed around the supporting structure to achieve controlled movement of the dispensing head. An issue with this arrangement is that incremental tolerance creep is incurred from the overextension of the winch cables and complex mathematics to define the coordinates of movement for the dispensing head.

Another problem with known arrangements of FDM 3D Printers, for the context of construction 3D Printing, is that without mechanical assistance devices such as overhead cranes, assembly of the device is not possible, or problematic, due to the bulky nature of the devices. This creates a limitation to the deployment and application of such devices where it is not possible to permit the use of mechanical assistance devices.

Brief Summary of the Invention

According to the first aspect of the present invention there is provided a cable driven 3D printing device comprising; at least three but generally four or more structural support legs wherein at least six but typically eight or more independently controllable motorised cable winch units are mounted, of which, in typical arrangements, two cable winch units are mounted per structural support leg, each of said cable winch units having; a motorised mechanism that, through operation of the motorised mechanism, generates movement of said cable winch unit along the "Z" axis of the respective structural support leg; a winch cable and associated spooling system, capable of co-ordinated winding and unwinding of said winch cable; a cable runner and associated operation mechanism wherein said cable ruimer is connected to or into the respective cable winch unit; a sensory device capable of measuring precise winch cable extension length; a sensory device capable of measuring precise elevation of said unit along the "Z" axis of the respective structural support leg; a material dispensing head mounting cradle wherein each of said cable winch unit winch cables are coupled to; a single material dispensing head, having a top and a bottom wherein the dispensing head mounting cradle is coupled to; an array of additional structural supports mounted at the top and or bottom of the structural support legs; an adjustable floor mount coupled to each of the structural support legs for reconciling alignment errors in the structural support legs; a material dispensing unit coupled to the dispensing head for delivering forming materials to the dispenser head and a controller for processing G-CODE files and enacting operational commandments to the cable winch units, dispensing head and material dispensing unit.

In a preferred embodiment, the structural support legs and additional structural supports comprise a plurality of standardised interlocking segments in which the total available print area is increased or decreased by way of adding or subtracting said segments. Advantageously, this allows the 3D Printing device to be customised to the volume requirements of each respective article for manufacture. Configuring the 3D Printing Device with a greater number of segments produces a larger area of operation for the material dispensing head.

Preferably, in the 3D Printing Device, die cable winch units will provide a motorised mechanism that engages with the structural support legs to produce the '2" axis described above. This may embody as a gear and track arrangement, but other arrangements have been contemplated.

In a second aspect of the present invention there is provided at least three but typically four or more adjustable floor mounts wherein each adjustable floor mount is coupled to a structural support kg along the vertical plane ("Z" axis). The adjustable floor mounts provide a means of adjusting the angle of ascension of the respective structural support leg by way of altering some adjusting mechanism. Advantageously, this provides a means of rectifying alignment errors incurred from deploying the 3D Printing Device on uneven grounding which may incur tolerance drift in the articles of manufacture.

Two embodiments of the adjustable floor mount aspect have been contemplated herein. In a first preferred embodiment of the adjustable floor mount there is provided a plurality of adjustable feet mounted to a plurality of protrusions from the base piece wherein each adjustable foot features an adjustment screw that, through winding or unwinding of the adjustment screw will raise the respective protrusion and hence alter the angle of ascent of the adjustable floor mount, thereby changing the angle of ascent of the coupled structural support leg.

In a second embodiment of the adjustable floor mount, a ball joint is provided, coupled between the adjustable floor mount and die respective structural leg support. The angle of ascent of the structural support leg in this embodiment is altered by loosening a fixture mechanism on the ball joint and then manually moving the ball joint to the desired angle of ascent. In this embodiment the ball joint may be fixed at the desired -ingle by way of locking plates or some other fixing mechanism. This embodiment may also feature a mechanism to fix the adjustable floor mount to the ground such as a large screw that physically embeds into the ground below the adjustable floor mount.

In a third aspect of the present invention there is provided a material dispensing head having a top and a bottom wherein the top is coupled to a material dispensing unit, preferably via a flexible hose, and the bottom is having a material exit orifice for dispensing provided materials onto a base member. Preferably, the material dispensing head will comprise a mechanism for adjusting the material exit orifice diameter. In an embodiment of the material dispensing head, a multiplicity of overlapping nozzle plates, each being coupled to an actuator via a control rod, are provided wherein the actuators are operated to extend outward, or retract inward the nozzle plates thereby reducing or increasing the diameter of the nozzle exit orifice.

In a fourth and final aspect of the present invention there is provided a means of electrically powering the 3D Printing device by way of electrically coupling the controller to a power source. In one embodiment of the present invention a battery and solar array system is provided.

Advantageously this allows the present invention to be operated in conditions where a mains power source is not readily available, so long as there is sufficient exposure to the sun to charge the battery system with the solar array. The individual aspects of the 3D Printing device are powered through the controller and the controller is connected to the mains, battery and solar array system or other electrical powering means.

Brief Description of the Drawinas

Preferred embodiments of the present invention will now be described, by way of example only, with reference to the following drawings in which: FIG. I is a perspective view of a 3D Printing Device showing some aspects of a preferred embodiment; FIG. 2 is a birds-eye view of a preferred embodiment of the present invention arranged to feature four structural support legs; FIG. 3 is a birds-eve view of a preferred embodiment of the present invention arranged to feature eight structural support legs; FIG. 4 is a side view of a preferred embodiment of the present invention arranged to feature four structural support legs: FIG. 5 is a close-up perspective view of a preferred embodiment of the material dispensing head, material dispensing head mounting cradle and coupled winch cables; FIG. 6 is a close-up exploded view of a preferred embodiment of the material dispensing head; FIG. 7 is a close-up perspective view of a preferred embodiment of a cable winch unit mounted to a respective structural support leg; FIG. 8 is a close-up exploded view of a preferred embodiment of the cable winch unit; FIG. 9 is a diagram showing a preferred embodiment of the cable winch unit mechanism for traversing along the 7" axis of the structural support leg; FIG. ID is a close-up perspective view of a preferred embodiment of the adjustable floor mount; FIG. 11 is a close-up perspective view of a second preferred embodiment of the adjustable floor mount; FIG. 12 is a close-up exploded view of the second preferred embodiment of the adjustable floor mount.

Detailed Description of a Preferred Embodiment

FIG. 1 is a perspective view of a 3D Printing Device 100 showing some aspects of a preferred embodiment. The device 100 is arranged such that eight cable winch units 1-8 are mounted to four vertically fixed structural support legs 23-26 with two cable winch units 1-8 mounted per structural support leg 23-26. Each of the eight cable winch units 1-8 are presenting a partially winded winch cable 11-18 coupled to a material dispensing head 9. By way of winding certain winch cables 11-18 and unwinding others, controlled movement of the material dispensing head 9 can be achieved.

In this embodiment, each structural support leg 23-26 is married with two cable winch units 1-8 having an even plurality of topmost cable winch units 1-4 and bottom cable winch units 5-8.

The topmost cable winch units 1-4 by way of controlled winding or unwinding the respective winch cables 11-14 maintain or manipulate the desired vector along the "Z" axis of the print envelope, The bottommost cable winch units 5-8 by way of controlled winding or unwinding of the respective winch cables 15-18 maintain or manipulate the desired vector along the "X" and "Y" axis of the print envelope.

To achieve controlled movement of the material dispensing head 9 across three degrees of freedom X. Y and z, a controller (not pictured), being suitably electrically married to the cable winch units 141, takes reference of the current extension length of each of the said winch cables 11-18 and by way of trigonometric principles calculates the current vector of the material dispensing head 9 within a virtual cartesian grid. The controller then uses the calculated location of the material dispensing head 9 to determine the required changes in winch cable I II 8 extension lengths to achieve the next co-ordinate within the virtual cartesian grid and commands the cable winch units 1-8 to wind or unwind the respective winch cables 11-18 in accordance.

Cartesian co-ordinates are instructed by way of inputting an instructional code file known as (1-CODE or AMF file. G-CODE is generated by first modelling the desired article of manufacture

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in CAD Software, then converting the CAD Model into G-CODE through specialised 3D Printing software. The G-CODE instruction is electrically enacted by the controller in expressed execution of; the material dispensing head 9 to control the flow of material being extruded; The cable winch units 1-8 for instructions on winch cable 11-18 extension lengths and "Z" axis elevation of the cable winch units 1-8; The material dispensing unit 42 for material flow and pressure to the material dispensing head 9.

To reduce calculation complexity and incremental errors in winch cable 11-18 extension length a motorised mechanical means (see FIG. 8: 67-70) is provided in the cable winch units 1-8 to allow for traversal movement along the "Z" axis of the structural support legs 23-26 by each respective cable winch unit 1-8. On completion of each layer of the print, the cable winch units 1-8 will all raise in an upward motion along the "Z" axis of the structural support legs 23-26 by an amount equal to the height of a single layer of printed material.

In a preferred embodiment of the 3D Printing device 100 displayed in FIG. 1, the structural support legs 23-26 are mounted vertically to adjustable foot mounts 19-22 that provide a stable upright support to the structural support legs 23-26 and provide a means of adjustment to the angle of ascent of each structural support leg 23-26. Advantageously, this allows for a calibration phase during assembly of the 3D Printing Device 100 to better align each structural support leg 23-26 vertically, preventing tolerance creep being incurred due to the device 100 being deployed on uneven grounding.

In a preferred embodiment a sensing device is deployed within the structural support leg 23-26 and adjustable foot mount 19-22 to aid calibration comprising; a laser device located floating centrally in the topmost segment of the structural support leg 23-26 with the lasers activating face pointing downward; and a calibrated light sensor fixed centrally inside the adjustable floor mount 19-22 with its sensor facing upward. When in operation the laser will fire a beam vertically down that will hit the sensor only when the structural support leg 23-26 is located at the correct angle. It is considered that it may be possible to automate the calibration procedure through use of some motorised mechanical means within die adjustable foot mount 19-22.

In a preferred embodiment shown in FIG.1 there is a plurality of additional structural supports 28-31 fixed to the top of the structural support legs 23-26 and fixed to the adjustable floor mounts 19-22. Advantageously, this provides the device 100 with greater rigidity and reduces tolerance drift caused by deflection of the structural support mounts 19-22 and displacement of the adjustable floor mounts 19-22 when in operation.

In a preferred embodiment, the structural support legs 23-26 and additional structural supports 28-31 comprise a plurality of standardised interlocking segments in which the total available print area is increased or decreased by way of adding or subtracting said segments Advantageously, this allows the 3D Printing device 100 to be customised to the volume requirements of each respective article for manufacture Configuring the 3D Printing Device 100 with a greater number of segments produces a larger area of operation for the material dispensing head 9.

The 3D Printing Device 100 may be electrically powered by way of a solar array and battery system (not pictured). The solar array and battery' system is connected to the controller as a replacement to a mains connection and the controller distributes the electrical energy to the cable winch units 1-8, material dispensing head 9 and material dispensing unit 42.

Moving briefly onto FIG. 2 showing a birds-eye view of an embodiment of the present invention arranged to feature four structural support legs 23-26, there is provided a material dispensing unit 42 located on the ground 27 adjacent to the 3D Printing device 90 that couples to the material dispensing head 9 via a flexible hose 10. The material dispensing unit 42 provides a steady and controllable flow of materials for manufacture to the material dispensing head 9 and is having; a materials mixing chamber; an exit orifice for dispensing to the material dispensing head 9 via the flexible hose 10; and a pumping system for maintaining a steady and controllable flow of materials for manufacture. The specific arra. ngements for the material dispensing unit 42 are not defined herein and are assumed, in this instance, to be by way of known means. The material dispensing unit 42 may deliver an array of different materials to the material dispensing head 9 including, but not limited to; concrete, clay or thermoplastics. The operations of the material dispensing unit 42 will be controlled by a controller (not pictured) that is suitably electronically married to the material dispensing unit 42.

A heating element may be deployed in the material dispensing head 9, hose 10 and material dispensing unit 42 to maintain a stable material temperature before it is extruded out of the material dispensing head 9. Advantageously this would prevent materials for manufacture freezing or becoming too viscous to extrude in cold climates. In a preferred embodiment it has been contemplated that the heating element may comprise an electrical induction mesh within the flexible hose 10 skin; an electrical induction coil in the material dispensing head 9: and an electrical induction coil in the material dispensing unit 42.

Moving on briefly to FIG. 3 showing a birds-eye view of a preferred embodiment of the present invention arranged to feature eight structural support legs. This arrangement may be deployed for printing articles of manufacture that are of greater volume to provide the material dispensing head 9 with improved control and stability. It is not considered what may be the maximum number arrangement of stmctural support kg assemblies, the minimum arrangement is known to be three.

Briefly moving to FIG. 4 there is provided a side view of a preferred embodiment of the present invention arranged to feature four structural support legs 23-26 showing the cable winch units 1-8 desired direction for freedom of movement along the '2" axis of the print envelope. The flexible hose 10 coupling the material dispensing head 9 and material dispensing unit 42 is guided over the additional support structure 28-31 to prevent clashing with the cable winch units 1-8 or winch cables 11-18.

FIG. 5 is showing a close-up perspective view of a preferred embodiment of the material dispensing head 9, material dispensing head mounting cradle 39 and coupled winch cables 11- 18. Each of said winch cables 11-18 are having a link 31-38 fixed to the coupling end of said winch cables 11-18 that interfaces with the material dispensing head mounting cradle 39. Preferably, the links 31-38 are having at least two parts that allow a degree of freedom of movement in the X, Y and Z axis of said link 31-38. Advantageously, this allows the winch cables 11-18 to operate at a range of angles to the material dispensing head 9 without incurring excessive stress, strain or print tolerance drift.

In a preferred embodiment the material dispensing mounting cradle 39 is fixed to the material dispensing head 9 via a bolted flange on the external face of the material dispensing head 9, however other arrangements have been considered. One such arrangement is a two-piece mounting cradle 39, split into equal halves along the vertical axis that seats within a groove on the outer face of the material dispensing head 9 and is secured by bolting means or other mechanical fastening devices presented on the mounting cradle 39. In another embodiment, the material dispensing mounting cradle 39 is formed as a permanent outer feature of the material dispensing head 9. It is preferred for the mounting cradle 39 and material dispensing head 9 to be separate entities. Advantageously, this would allow for the material dispensing head 9 to be removed in situ during printing activities for maintenance or overhaul whilst still maintaining the last print coordinates with the mounting cradle 39.

In a preferred embodiment the flexible hose 10 is coupled to the material dispensing head 9 with a hose fixing mechanism 40 Preferably, the hose fixing mechanism 40 would be fixed to the material dispensing head 9 with a bolted flange or other mechanical fastening mechanism.

Preferred embodiments of the material dispensing head 9 nozzle exit orifice 41 comprise a mechanical feature that allows the nozzle exit orifice 41 to expand or contract through some means of actuation. Advantageously, this allows the thickness of the material being extruded from the material dispensing head 9 to be modified providing a benefit to the overall print time for each layer by; contracting the nozzle exit orifice 41 to perform an initial, detailed outline of the intended print layer; then expanding the nozzle exit orifice 41 to fill in the outlined print layer, thus reducing the overall delta movement of the material dispensing head 9 to complete a print laver and in turn reducing the overall print time.

In FIG. 6 there is a close-up exploded view of a preferred embodiment of the material dispensing head 9. In this preferred embodiment, the material dispensing head 9 comprises; a dispensing head housing 43 on which, is mounted a plurality of actuators 44-49; a plurality of nozzle plates 56-61 which are mounted to the dispensing head housing 43 by some manoeuvrable mechanism and overlap to some degree when assembled; a plurality of control rods 50-55 that are coupled to the actuators 44-49 and the nozzle plates 56-61 wherein by engaging the actuators 44-49 causes the nozzle plates 56-61 to separate in an outward direction or contract in an inward direction, dependent on the direction of operation of the actuators 44- 49. thus increasing or decreasing the nozzle exit orifice 41 diameter.

In a second aspect of a preferred embodiment of the material dispensing head 9 shown in FIG. 6 there is a screw pump drive mechanism 63 and screw pump 62 seated freely within the dispensing head housing 43 that, through operation of the screw pump drive mechanism 63 rotates the screw pump 62 clockwise or counter-clockwise in a controlled fashion.

Advantageously, this provides a secondary means of controlling the flow of fluid materials through the materials dispensing head 9 and out of the nozzle exit orifice 41.

Moving briefly to FIG. 7 there is a close-up perspective view of a preferred embodiment of a cable winch unit I mounted to a respective structural support leg 23 wherein the cable winch unit 1 is having a cable runner 64 and associated control mechanism 65 for guiding the winch cable Ii. In a preferred embodiment the cable runner forms an element of the spool cover 73 and the cable runner associated control mechanism 65 comprises; a motor, a gearing system for stepping down the motor RPM speed and a cable pulley system. When the motor is electrically engaged to rotate in one direction the cable runner 64 raises and when the motor is electrically engaged to rotate in the opposite direction the cable runner 64 lowers.

FIG. 8 shows a close-up exploded view of a preferred embodiment of the cable winch unit 1-8 wherein the spool 74, having a top and a bottom, provides a geared element on its top that engages with the spool gear 75. In this preferred arrangement, the spool 74 is mounted to the material dispensing head housing 76 radially, preferably having a needle roller bearing between the housing 76 and spool 74. In this embodiment the spool 74 turns radially around the dispensing head housing 76. The spool gear 75 is activated by a motor 77 which may further comprise a step-down gearbox to reduce motor RPM speed. When the motor 77 is electrically engaged, the spool gear 75 turns the spool 74 whereby winding or unwinding the winch cable II, dependent on the rotational direction of the motor 77. Preferably, the spooling system described above also comprises a spool cover 73, beneficially to protect the spooling system from foreign objects The spool cover 73 may further comprise a sensing device 78 that takes precise measurement of the total angle of rotation of the spool gear 75 or spool 74. In a second preferred embodiment, the sensing device 78 is located in the cable runner 64 sub-assembly and instead, takes precise measurement of the winch cable II extension/retraction length.

The present invention is also having a motorised mechanism within the cable winch unit 1-8 for guiding the cable winch unit 1-8 up or down the structural support leg 23-26 along the "Z" axis. In a preferred embodiment shown in FIG. 8 the motorised mechanism consists of two motors 69-70 and two gears 67-68, each motor 69-70 haying a corresponding gear 67-68 aligned in parallel with the structural support leg 23-26 and engaging into a track gear feature 79 on the outer surface of the structural support kg 23. The arrangement discussed above is further illustrated in FIG. 9 which shows a diagram of a preferred embodiment of the cable winch unit mechanism for traversing along the "Z-axis of the stmctural support leg 23. The motors 69-70 rotate in opposite directions to one another with one motor 69 arid gear 67 arranged engaging on one side of the structural support leg 23 track gear feature 79, and the other motor 70 and gear 68 arranged engaging the opposite side of the structural leg 23 track gear feature 79. When the motors 69-70 are electrically engaged to contra-rotate, dependent on the motor 69-70 rotation pattern, the cable winch unit 1 will either raise or lower along the -Z" axis of the structural support leg 23. In other embodiments, the motorised mechanism may consist of only one motor 69-70 and gear 67-68 engaging only one track gear feature 79. Other embodiments may not necessitate a geared arrangement but instead use a smooth track or variable electromagnetic field.

FIG. ID shows a close-up perspective view of a preferred embodiment of the adjustable floor mount 19-22. This embodiment comprises; a plurality of adjustable feet 82-84 having a top and bottom, wherein the bottom face is placed on a suitably prepared ground 27 and a slot recess is provided on the top face; a foot housing 81 having a top and a bottom wherein a plurality of evenly spaced struts are located at or on the bottom face of the foot housing 81 and the top face is having a flange or other fastening feature; a housing cover 80 with a flange or other fastening feature that couples with the foot housing 81.

In this preferred embodiment of the adjustable floor mount 19-22 the foot housing 81 has a central, vertically aligned slot in order to couple to the structural support leg 23-26 and a hollow cavity within the body of the foot housing 81. The hollow cavity may be filled with cement, sand or other weighting material, beneficially to provide each adjustable floor mount 19-22 with added mass for greater stability of the final assembly of the 3D Printing Device 100. The struts protruding from the bottom face of the foot housing 8 I are slotted into each of the plurality of adjustable feet 82-84, wherein one adjustable foot 82-84 is fitted to each strut and are secured with adjusting screws 85-87. To alter the angle that the adjustable floor mount 19-22 is seated, the adjusting screws 85-87 are either winded or unwinded. Winding in an adjustable screw 85- 87 raises the respective strut in the slot of the respective adjustable foot 82-84 providing a method of altering the angle of the foot housing 81. The housing cover 80 is fastened to the top of the foot housing 81 by way of said bolted flange or other fastening device in order to contain said weighting materials, for example; sand or cement.

Finally, moving on briefly to FIG. 11 there is shown a close-up perspective view of a second preferred embodiment of the adjustable floor mount 19-22 wherein the adjustable floor mount 19-22 comprises; a foot housing 89, a ball joint assembly 88, a weight distribution plate 90 and a ground screw 91. In this arrangement, the foot housing 89, having a top and a bottom, is seated atop a weight distribution plate 90 on its bottom face and is secured to the ground 27 by a ground screw 91 that is wound into the ground 27 through a central recess within the foot housing 89. Advantageously, this secures the adjustable floor mount 19-22 to a location on the ground 27, providing the hill 3D Printer Device 100 with a high level of rigidity thus minimising adjustable floor mount 19-22 displacement when the device 100 is in operation.

Fixed to the top face of the foot housing 89 via a bolted flange or other fastening device is a ball joint assembly 88. In FIG. 12, showing a close-up exploded view of the second preferred embodiment of the adjustable floor mount 19-22, the constituent components of the ball joint assembly 88 can be seen. In this embodiment the ball joint assembly 88 comprises; a lower ball joint housing 92, having a top and a bottom wherein the bottom face of the lower ball joint housing 92 is coupled to the top face of the foot housing 89 by means of a bolted flange or other fastening device; a ball joint 93 wherein the ball joint 93 is seated inside the curved inner face of the lower ball joint housing 92 and has a top and bottom wherein the bottom features a spherical body and the top features a protruded feature to slot into or on the structural support leg 23-26 and a top ball joint housing 94, having a top and a bottom, wherein the bottom face of the top ball joint housing 94 is coupled to the top face of the lower ball joint housing 92 by means of a bolted flange or other fastening device. When the top ball joint housing 94, ball joint 93 and lower ball joint housing 92 are assembled the ball joint 93 has a degree of angular freedom through an opening in the top ball joint housing 94 that can be adjusted to better align the stnictural support leg 23-26 to the desired vertical position. The top ball joint housing 94 also features a fixing device 95 of some description to fix the ball joint 93 into position once alignment has been achieved. In a preferred embodiment shown in FIG. 12 the fixing device 95 is a plurality of locking plates that assert pressure on the ball joint 93 when engaged.

Claims (16)

1. Claims A 3D Printing device (100) comprising: at least three structural support legs (23-25) fixed to at least six independently controllable motorised cable winch units (1-3, 5-7) in which, at least two cable winch units (1-3, 5-7) are mounted per structural support leg (23-25), each of said cable winch units (1-3, 5-7) having; a motorised mechanism that, through operation of the motorised mechanism, generates movement of said cable winch unit (1-3, 5-7) along the "Z" axis of the respective structural support leg (23-25); a winch cable (11-13, 15-17) and associated spooling system, capable of co-ordinated winding and unwinding of said winch cable ( 11-13, 15-17); a cable runner (64) and associated operation mechanism (65) wherein said cable runner (64) is connected to or into the respective cable winch unit (1-3, 5-7); a sensory device (78) capable of measuring precise winch cable extension length.a single material dispensing head mounting cradle (39) wherein each of said cable winch unit winch cables (11-13, 15-17) are coupled to; a single material dispensing head (9), having a top and a bottom wherein the dispensing head mounting cradle (39) is coupled to; a material dispensing unit (42) coupled to the material dispensing head (9) for delivering forming materials to said material dispensing head (9); and a controller for processing data for operation of the cable winch units (1-3, 5- 7). material dispensing head (9), material dispensing unit (42) derived from a G-CODE or other AMF file.
2. 2. A 3D Printing device (100) comprising: at least three structural support legs (23-25) fixed to at least six independently controllable motorised cable winch units (1-3, 5-7) in which, at least two cable winch units (1-3, 5-7) are mounted per structural support leg (23-25), each of said cable winch units (1-3, 5-7) having; a motorised mechanism that, through operation of the motorised mechanism, generates movement of said cable winch unit (1-3, 5-7) along the "Z' axis of the respective structural support leg (23-25); a winch cable (11-13, 15-17) and associated spooling system, capable of coordinated winding and unwinding of said winch cable (11-13, 15-17); a cable runner (64) and associated operation mechanism (65) wherein said cable runner (64) is connected to or into the respective cable winch unit (1-3, 5-7); a sensory device (78) capable of measuring precise winch cable (11-13, 15-17) extension length; a single material dispensing head (9), having a top and a bottom wherein each of said cable winch unit winch cables (11-13, 15-17) are coupled to fixing features on the outer shell of the material dispensing head (9); a material dispensing unit (42) coupled to the material dispensing head (9) for delivering foil/ling materials to said material dispensing head (9); and a controller for processing data for operation of the cable winch units (1-3, 57). material dispensing head (9), material dispensing unit (42) and other associated mechanisms derived from a G-CODE or other AMF file.
3. 3. The 3D Printing Device (100) of claim 1 or 2 additionally comprising a sensory device (71) per cable winch unit (1-3, 5-7) capable of measuring precise elevation of said cable winch unit (1-3, 5-7) along the axis of the respective structural support leg (23-25);
4. 4. The 3D Printing Device (100) according to any above claim wherein an array of additional structural supports (28-30) mounted at the top and/or bottom of the structural support legs (23-25) is included.
5. 5. The 3D Printing Device (100) according to any above claim wherein the structural support legs (23-25), and/or additional structural supports (28-30) are divided into standardised, interlocking segments to allow for a variable print envelope through the addition or subtraction of said standardised segments
6. 6. The 3D Printing Device (100) according to any above claim wherein the device is electrically powered by a solar array and battery system.
7. 7. The 3D Printing Device (100) according to any above claim wherein the structural support legs (23-25) are coupled to an adjustable floor mount (19-21) for reconciling alignment errors in the structural support legs (23-25).
8. 8. The 3D Printing Device (100) according to claim 7 wherein the adjustable floor mount ( 19-21) features a ball joint (88) for radial adjustment of the respective stmctural support legs (23-25).
9. 9. The 3D Printing Device (100) according to claim 7 or 8 wherein the adjustable floor mount (19-21) features a ground screw locking feature (91) for fixing the structural support leg (23-25) and adjustable floor mount (19-21) assembly to the ground (27).
10. 10. The 3D Printing Device (100) according to claim 7 or 8 wherein the adjustable floor mount (19-21) features a plurality of independently adjustable mounting feet (82-84).
11. 11. The 3D Printing Device (100) according to any above claim wherein the material dispensing head (9) features a mechanism (41) for adjusting the volume of material extruded by expanding or contracting the nozzle exit orifice.
12. 12. The 3D Printing Device (100) according to claim 11 wherein the material dispensing head (9) features a multiplicity of overlapping nozzle plates (56-61) whereby a multiplicity of actuators (44-49) and control rods (50-55) are actuated in order to expand or contract the material dispensing head (9) exit orifice.
13. 13. The 3D Printing Device (100) according to any above claim wherein the material dispensing head (9) features a Pump screw (62) and driving mechanism (63) whereby actuation of a pump screw (62) and driving mechanism (63) achieves control of the flow of material through the material dispensing head (9) exit orifice.
14. 14. The 3D Printing Device (100) according to any above claim wherein the material dispensing head (9) and material dispensing unit (42) are coupled together additionally with a flexible hose (10).
15. 15. The 3D Printing Device (100) according to claim 14 wherein the material dispensing head (9), material dispensing unit (42) mid flexible hose (10) feature a heating mechanism for controlling and maintaining a stable material temperature prior to depositing the material onto the base member.
16. 16. The 3D Printing Device (100) according to any above claim wherein the cable winch unit (1-3, 5-7) motorised mechanism comprises at least one motor (69-70) and at least one gear (67-68) that engages with a track feature (79) on the outer face of the structural support legs (23-25).