JP2016518267A - 三次元印刷法 - Google Patents
三次元印刷法 Download PDFInfo
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- JP2016518267A JP2016518267A JP2016504385A JP2016504385A JP2016518267A JP 2016518267 A JP2016518267 A JP 2016518267A JP 2016504385 A JP2016504385 A JP 2016504385A JP 2016504385 A JP2016504385 A JP 2016504385A JP 2016518267 A JP2016518267 A JP 2016518267A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
- B29C48/154—Coating solid articles, i.e. non-hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/14—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length of filaments or wires
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/02—Making granules by dividing preformed material
- B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/12—Making granules characterised by structure or composition
- B29B9/14—Making granules characterised by structure or composition fibre-reinforced
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/92—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
- B29C64/209—Heads; Nozzles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
- B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/382—Automated fiber placement [AFP]
- B29C70/384—Fiber placement heads, e.g. component parts, details or accessories
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92076—Position, e.g. linear or angular
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/92571—Position, e.g. linear or angular
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
- B29C2948/92704—Temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92819—Location or phase of control
- B29C2948/92857—Extrusion unit
- B29C2948/92904—Die; Nozzle zone
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/252—Drive or actuation means; Transmission means; Screw supporting means
- B29C48/2528—Drive or actuation means for non-plasticising purposes, e.g. dosing unit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
Abstract
Description
Claims (104)
- 部品を製造するための方法であって、
空隙を含まないコア強化フィラメントを押出しノズルに送り込むステップであって、前記コア強化フィラメントがコア及び前記コアを取り囲むマトリクス材料を含むステップと、
前記マトリクス材料の融解温度よりも高く前記コアの融解温度よりも低い温度まで、前記コア強化フィラメントを加熱するステップと、
前記コア強化フィラメントを押出して前記部品を形成するステップと、を含む、方法。 - 前記マトリクス材料が熱可塑性樹脂を含んでいる、請求項1に記載の方法。
- 前記コア強化フィラメントを押出すステップが、前記コア強化フィラメントを圧縮下で押出すステップをさらに含む、請求項1に記載の方法。
- 前記コア強化フィラメントを押出すステップが、前記コア強化フィラメントを支えのない領域を越えて押出すステップをさらに含む、請求項1に記載の方法。
- 前記コア強化フィラメントで頑丈なシェルを形成するステップをさらに含む、請求項4に記載の方法。
- 前記コア強化フィラメントを、部品の第1の部分において第1の方向に押し出し、前記部品の第2の部分において第2の方向に押出すステップをさらに含む、請求項1に記載の方法。
- 前記ノズルの出口において又はそれより上流において前記コア強化フィラメントを切断するステップをさらに含む、請求項1に記載の方法。
- 前記ノズルの前記出口と供給機構との間で前記コア強化フィラメントを切断するステップをさらに含む、請求項7に記載の方法。
- 前記コアが、電気的、光学的、及び流体的に伝導性のある構成要素のうちの少なくとも一つを含んでいる、請求項1に記載の方法。
- 統合された電気的構成要素、光学的構成要素、又は流体的構成要素のうちの少なくとも一つを有する部品を形成するステップをさらに含む、請求項9に記載の方法。
- 前記コアがマルチフィラメントコアである、請求項1に記載の方法。
- 前記コアが固体コアである、請求項1に記載の方法。
- 前記コア強化フィラメントを押出すステップが、前記押出しノズルの丸みを帯びた出口を通して前記コア強化フィラメントを押出すステップをさらに含む、請求項1に記載の方法。
- 前記コアが連続コアである、請求項1に記載の方法。
- 前記コアが半連続コアである、請求項1に記載の方法。
- 関連する供給機構の力の閾値よりも前記フィラメントに印加される引きずり力の方が大きいときに、前記フィラメントを前記ノズルから引き出すステップをさらに含む、請求項1に記載の方法。
- 三次元印刷機と共に使用するためのフィラメントであって、
マルチフィラメントコアと、
前記マルチフィラメントコアを取り囲むマトリクス材料と、を備えており、前記マトリクス材料が、実質的に前記マルチフィラメントコアの断面全体に含浸され、前記フィラメントが、実質的に空隙を含まないものである、フィラメント。 - 前記フィラメントが、三次元印刷機での使用のためのサイズ及び形状となされている、請求項17に記載のフィラメント。
- 前記フィラメントが、0.010インチ以上0.030インチ以下の外径を有している、請求項17に記載のフィラメント。
- 前記マルチフィラメントコアの融解温度が、前記マトリクス材料の融解温度よりも高い、請求項17に記載のフィラメント。
- 前記マルチフィラメントコアが、電気的に伝導性、光学的に伝導性、流体的に伝導性のうちの少なくとも一種である、請求項17に記載のフィラメント。
- 前記マトリクス材料が、アクリロニトリルブタジエンスチレン、エポキシ、ビニル、ナイロン、ポリエーテルイミド、ポリエーテルエーテルケトン、ポリアクチック酸(polyactic acid)、及び液晶ポリマーのうちの少なくとも一種を含んでいる、請求項17に記載のフィラメント。
- 前記マルチフィラメントコアが、炭素繊維、アラミド繊維、ガラス繊維、銅、銀、金、錫、光学繊維、及び可撓性チューブのうちの少なくとも一種を含んでいる、請求項17に記載のフィラメント。
- 前記コアが連続コアである、請求項17に記載のフィラメント。
- 前記コアが半連続コアである、請求項17に記載のフィラメント。
- 部品を製造するための方法であって、
フィラメントを加熱押出しノズルに送り込むステップ、及び
前記加熱ノズルの出口の又はそれより上流の位置において前記フィラメントを切断するステップ、を含む、方法。 - 前記位置が、前記ノズル出口と供給機構との間である、請求項26に記載の方法。
- 前記位置が、前記ノズル出口にある、請求項26に記載の方法。
- 前記フィラメントを切断するステップが、前記ノズル内の前記フィラメントに向けられた刃を用いて前記フィラメントを切断するステップをさらに含む、請求項28に記載の方法。
- 前記フィラメントを切断するステップが、前記ノズル出口の周囲に沿って配置され且つ堆積表面に面するように配向された刃を用いて前記フィラメントを切断するステップをさらに含む、請求項28に記載の方法。
- 前記フィラメントを切断するステップが、前記フィラメントの温度が前記フィラメントのガラス転移温度未満である位置において前記フィラメントを切断するステップをさらに含む、請求項26に記載の方法。
- 前記フィラメントを切断するステップが、前記フィラメントのコアを切断するステップをさらに含む、請求項26に記載の方法。
- 前記切断されるフィラメントの下流側部分を前記加熱押出しノズルから引き出すために、前記切断されるフィラメントの前記下流側部分に引張力を印加するステップをさらに含む、請求項26に記載の方法。
- 前記切断されるフィラメントの前記下流側部分に力を印加するステップが、前記切断されるフィラメントの前記下流側部分内のコアに力を印加するステップをさらに含む、請求項33に記載の方法。
- 前記切断されるフィラメントの下流側部分を押出すために、前記切断されるフィラメントの上流側部分に圧縮力を印加するステップをさらに含む、請求項26に記載の方法。
- 前記フィラメントを切断するステップが、前記加熱押出しノズルの前記出口を閉塞するステップをさらに含む、請求項26に記載の方法。
- 前記フィラメントを切断するステップが、前記切断されるフィラメントの下流側部分に押出し力が印加されるのを防止するステップをさらに含む、請求項26に記載の方法。
- 前記フィラメントを切断するステップが、前記フィラメントをホットナイフで切断するステップを含む、請求項26に記載の方法。
- ノズル出口を含む加熱押出しノズルと、
前記加熱押出しノズルにフィラメントを送り込むように構成され且つ配置された供給機構と、
前記加熱ノズル出口の又はそれより上流の位置において前記フィラメントを切断するように構成され且つ配置された切断機構と、を備えている、三次元印刷機。 - 前記位置が、前記ノズル出口と前記供給機構との間である、請求項39に記載の三次元印刷機。
- 前記位置が、前記ノズル出口にある、請求項39に記載の三次元印刷機。
- 前記切断機構が、前記ノズル内にあるときの前記フィラメントに向けられた刃を備えている、請求項41に記載の三次元印刷機。
- 前記切断機構が、前記ノズル出口の周囲に沿って配置され且つ堆積表面に面するように配向された刃を備えている、請求項42に記載の三次元印刷機。
- 前記位置が、前記フィラメントの温度が前記フィラメントのガラス転移温度未満である場所で前記フィラメントを切断するように選択されている、請求項39に記載の三次元印刷機。
- 前記切断機構が、前記フィラメントのコアを切断するように構成され且つ配置されている、請求項39に記載の三次元印刷機。
- 前記切断機構が、作動されたときに前記ノズル出口を閉塞する、請求項39に記載の三次元印刷機。
- 前記切断機構が、前記フィラメントの下流側部分に前記供給機構が押出し力を印加するのを防止する、請求項39に記載の三次元印刷機。
- 前記供給機構が、前記切断機構より上流の前記フィラメントに力を印加する、請求項39に記載の三次元印刷機。
- 前記切断機構がホットナイフである、請求項39に記載の三次元印刷機。
- フィラメントを受け入れるように構成され且つ配置されたノズル入口と、
前記ノズル入口と流体連通しているノズル出口とを備えており、前記フィラメントの経路に対して直角な前記ノズル出口の断面積が、前記フィラメントの前記経路に対して直角な前記ノズル入口の断面積よりも大きい、加熱押出しノズル。 - 前記ノズル入口と前記ノズル出口との間に配置されたチャネルをさらに備えており、前記チャネルが、前記フィラメントを支持するように構成され且つ配置されている、請求項50に記載の加熱押出しノズル。
- 前記チャネルが、実質的に直線で構成されている、請求項51に記載の加熱押出しノズル。
- 前記チャネルが、前記ノズルの冷却供給ゾーンである、請求項51に記載の加熱押出しノズル。
- 前記チャネルと前記ノズル出口との間に配置された空洞をさらに備えており、前記フィラメントの前記経路に対して直角な前記空洞の断面積が、前記フィラメントの前記経路に対して直角な前記第1のチャネルの断面積よりも大きい、請求項51に記載の加熱押出しノズル。
- 前記空洞が、前記ノズルの加熱ゾーンを含んでいる、請求項54に記載の加熱押出しノズル。
- 前記ノズル出口が、丸みを帯びた縁を備えている、請求項50に記載の加熱押出しノズル。
- 三次元印刷機と共に使用するためのフィラメントであって、
前記フィラメントの軸方向に延在する複数の別々のセグメントを含むコアと、
前記複数のセグメントを取り囲むマトリクス材料と、を備えており、
前記マトリクス材料が、実質的に前記コアの断面全体に含浸され、前記フィラメントが、実質的に空隙を含まないものである、フィラメント。 - 前記セグメントが、前記フィラメントの前記軸方向に沿って予め割り出された位置に配置されている、請求項57に記載のフィラメント。
- 前記セグメントのうちの少なくとも幾つかが、前記フィラメントの前記軸方向に沿って重なり合っている、請求項57に記載のフィラメント。
- 前記セグメントの平均長さが、前記三次元印刷機の加熱ゾーンの長さ以下である、請求項57に記載のフィラメント。
- ノズルの温度がフィラメントの融解温度を下回る前記ノズル出口の上流の位置に、前記フィラメントを位置決めするステップと、
印刷プロセス中に前記フィラメントを前記ノズル出口から外へ移動させるステップと、を含む、方法。 - 前記フィラメントが前記ノズル出口から外へ移動されるときに、前記ノズルの加熱ゾーンと前記フィラメントとを接触させるステップをさらに含む、請求項61に記載の方法。
- 前記加熱ゾーンに接触させるステップが、前記フィラメントを前記加熱ゾーンの方へ移動させるステップをさらに含む、請求項62に記載の方法。
- 前記フィラメントを移動させるステップが、前記フィラメントを移動させるために、前記フィラメントを座屈させるステップ及び前記ノズルを移動させるステップのうちの少なくとも一つをさらに含む、請求項63に記載の方法。
- 前記フィラメントが、前記加熱ゾーンに接触するまでは実質的に固体のままである、請求項61に記載の方法。
- 前記フィラメントが堆積されているときに、前記ノズル出口により前記フィラメントに圧縮力を印加するステップをさらに含む、請求項61に記載の方法。
- 前記フィラメントがコア強化フィラメントである、請求項61に記載の方法。
- フィラメントを支持するためのサイズと成され且つ配置された第1のチャネルから、ノズル出口と流体連通している空洞へ前記フィラメントを供給するステップを含む方法であって、前記フィラメントの経路に対して直角な前記空洞の断面積が、前記フィラメントの前記経路に対して直角な前記第1のチャネルの断面積よりも大きい、方法。
- 少なくとも前記ノズル出口に至るまで前記フィラメントが供給されるまで、前記フィラメントが前記空洞の壁に接触するのを防止するステップをさらに含む、請求項68に記載の方法。
- 前記フィラメントを融解させるために、前記フィラメントを前記壁又はノズル出口に接触させるステップをさらに含む、請求項69に記載の方法。
- 少なくとも前記ノズル出口に至るまで前記フィラメントが供給されるまで、前記フィラメントを実質的に固体の状態に維持するステップをさらに含む、請求項68に記載の方法。
- 前記フィラメントが堆積されているときに、前記ノズル出口により前記フィラメントに圧縮力を印加するステップをさらに含む、請求項68に記載の方法。
- 前記フィラメントがコア強化フィラメントである、請求項68に記載の方法。
- 前記チャネルが、前記ノズルの冷却供給ゾーンである、請求項68に記載の方法。
- フィラメントを形成するための方法であって、
コア強化フィラメントを形成するために、一つ以上の繊維と第1のマトリクス材料とを混合するステップと、
前記第1のマトリクス材料を前記一つ以上の繊維に含浸させるために、前記フィラメントに遠回り経路を通過させるステップと、を含む、方法。 - 前記遠回り経路が、少なくとも、第1の方向における第1の曲りと、第2の方向における第2の曲りとを含む、請求項75に記載の方法。
- 前記遠回り経路内の前記フィラメントの温度が、前記第1のマトリクス材料の融解温度よりも高く維持される、請求項75に記載の方法。
- 前記フィラメントに真空を印加するステップをさらに含む、請求項75に記載の方法。
- 前記フィラメントが、印刷機ヘッド内で前記遠回り経路を通過する、請求項75に記載の方法。
- 前記遠回り経路を選択的に直線状にするステップをさらに含む、請求項79に記載の方法。
- 前記フィラメント上に外側被覆を形成するために、前記フィラメントを第2のマトリクス材料と一緒に共押出しするステップをさらに含む、請求項75に記載の方法。
- 前記フィラメントに成形ダイを通過させるステップをさらに含む、請求項75に記載の方法。
- 前記フィラメントが冷えるときにその形状及びサイズを保持するために、前記フィラメントが前記成形ダイから出た後で前記フィラメントを支持するステップをさらに含む、請求項82に記載の方法。
- 前記一つ以上の繊維が、一つ以上の連続繊維である、請求項75に記載の方法。
- 前記一つ以上の繊維が、一つ以上の半連続繊維である、請求項75に記載の方法。
- コア強化フィラメント上に被覆材料で外側被覆を形成するために、前記コア強化フィラメント及び前記被覆マトリクス材料を共押出しするステップ、を含む、方法。
- 前記被覆付きコア強化フィラメントにダイを通過させるステップをさらに含む、請求項86に記載の方法。
- 前記コア強化フィラメントのマトリクス材料が、前記被覆材料とは異なる、請求項86に記載の方法。
- 前記コア強化フィラメントのマトリクス材料が、前記被覆材料と同じである、請求項86に記載の方法。
- 前記コア強化フィラメントのマトリクス材料が、前記被覆材料よりも高い融解温度を有する、請求項86に記載の方法。
- 前記コア強化フィラメントが、コア、及び前記コアを取り囲むマトリクス材料を含み、前記マトリクス材料が、実質的に前記マルチフィラメントコアの断面全体に含浸される、請求項86に記載の方法。
- 前記コア強化材料が、実質的に空隙を含まないものである、請求項91に記載の方法。
- 前記コアがマルチフィラメントコアである、請求項91に記載の方法。
- 部品を製造するための方法であって、
加熱押出しノズルにフィラメントを送り込むステップと、
ノズル出口から前記フィラメントを押出すステップと、
前記ノズルにより前記押出しフィラメントに圧縮力を印加するステップと、を含む、方法。 - 前記ノズルが圧縮力を印加するときに、前記ノズルにより前記押出しフィラメントを加熱するステップをさらに含む、請求項94に記載の方法。
- 前記加熱押出しノズルに前記フィラメントを送り込むステップが、前記加熱押出しノズルにコア強化フィラメントを送り込むステップをさらに含む、請求項94に記載の方法。
- 前記強化フィラメントが、前記押出しノズルに送り込まれるときには実質的に固体である、請求項96に記載の方法。
- 前記ノズルの丸みを帯びた縁が、前記押出しフィラメントに圧縮力を印加する、請求項94に記載の方法。
- 部品を製造するための方法であって、
印刷機ヘッドを使用して、第1のフィラメントを第1の所望のパターンでマトリクス材料の層内に堆積させるステップと、
前記マトリクス層の少なくとも一部分を硬化させて、前記堆積された第1のフィラメントを含む部品の層を形成するステップと、を含む、方法。 - 前記第1のフィラメントを切断し、且つ、印刷機ヘッドを使用して、第2のフィラメントを第2の所望のパターンでマトリクス材料の前記層内に堆積させるステップをさらに含む、請求項99に記載の方法。
- 前記マトリクス材料の少なくとも一部分を硬化させるステップが、ステレオリソグラフィを使用して前記マトリクス材料の少なくとも一部分を硬化させるステップをさらに含む、請求項99に記載の方法。
- 前記マトリクス材料の少なくとも一部分を硬化させるステップが、選択的レーザ焼結を使用して前記マトリクス材料の少なくとも一部分を硬化させるステップをさらに含む、請求項99に記載の方法。
- 前記マトリクス材料を実質的に前記第1のフィラメントの断面全体に含浸させるステップをさらに含む、請求項99に記載の方法。
- 含浸後の前記第1のフィラメントの断面が、実質的に空隙を含まないものである、請求項101に記載の方法。
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