WO2017182928A1

WO2017182928A1 - Simultaneous multi-nozzle deposition

Info

Publication number: WO2017182928A1
Application number: PCT/IB2017/052179
Authority: WO
Inventors: Prasad DASAPPA; Aravinda AGARWALLA; Gurunath POZHAL VENGU
Original assignee: Sabic Global Technologies B.V.
Priority date: 2016-04-22
Filing date: 2017-04-14
Publication date: 2017-10-26

Abstract

Additive manufacturing systems using multiple nozzles for depositing product material are described. The multiple nozzles can simultaneously construct different layers of the product being manufactured to expedite process.

Description

SIMULTANEOUS MULTI-NOZZLE DEPOSITION

RELATED APPLICATON

[0001] This application claims priority to and the benefit of U.S. Patent Application No. 62/326,448, filed April 22, 2016, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] This disclosure generally relates to additive manufacturing systems. More particularly, this disclosure concerns a system using multiple nozzles for simultaneous deposition of material in additive manufacturing. This disclosure also concerns devices and techniques for employing multiple nozzles and simultaneous deposition.

BACKGROUND

[0003] Additive manufacturing is a technology field whereby a three dimensional design is produced through adding material in deposited layers defining cross sections of the three dimensional design. A variety of techniques exist for conducting additive manufacturing by three-dimensional printing, including stereolithography, digital light processing, fused deposition modeling, selective laser sintering, selective laser melting, electronic beam melting, laminated object manufacturing, and others. One limitation of three-dimensional printing is the speed at which material can be provided to the structure.

[0004] For example, in fused deposition modeling, a single nozzle provides heated material to add to a single layer. The rate at which the three-dimensional object is manufactured is limited by the speed with which the carriage moving the nozzle can traverse the cross-section of the object, the rate at which printing material can be applied using the nozzle, the temperature of material adjacent that being applied (e.g., previous layer given time to solidify before supporting subsequent layer), et cetera.

SUMMARY

[0005] In an embodiment, aspects herein relate to three-dimensional printing systems comprising a first printing nozzle causing a first printing material to build at least a first portion of a printed component and a second printing nozzle causing a second printing material to build at least a second portion of the printed component. The second printing nozzle causes the second printing material to build at least the second portion of the printed component during at least a portion of the time when the first printing nozzle causes the first printing material to build at least the first portion of the printed component. The system further includes a positioning structure configured to position at least the first printing nozzle and the second printing nozzle during production of the printed component and a print controller configured to control at least the positioning structure during production of the printed component.

[0006] Various aspects will become apparent to those skilled in the art from the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

[0007] FIG. 1 illustrates a single nozzle embodiment of three-dimensional printing;

[0008] FIGS. 2A and 2B depict simultaneous multi-nozzle three-dimensional printing;

[0009] FIGS 3 depicts simultaneous multi-nozzle three-dimensional printing;

[0010] FIGS. 4A and 4B depict simultaneous multi-nozzle three-dimensional printing using a gantry arrangement;

[0011] FIGS. 5A and 5B depict simultaneous multi-nozzle three-dimensional printing using an alternative gantry arrangement;

[0012] FIGS. 6A and 6B depict simultaneous multi-nozzle three-dimensional printing using a robotic arm arrangement;

[0013] FIGS. 7A and 7B depict simultaneous multi-nozzle three-dimensional printing using a hybrid robotic arm and gantry arrangement;

[0014] FIG. 8 depicts an example flow of multi-nozzle three-dimensional printing based on the movement of single nozzles in reference to one another;

[0015] FIG. 9 depicts an example flow of multi-nozzle three-dimensional printing based on the movement of single nozzles in reference to one another using a waiting scheme;

[0016] FIG. 9 depicts an example flow of multi-nozzle three-dimensional printing based on the movement of single nozzles in reference to one another without using a waiting scheme;

[0017] FIG. 11 illustrates an example embodiment wherein multiple features of a printed product are simultaneously produced; and [0018] FIG. 12 illustrates example time savings using multiple nozzles using a graph of printing times.

DETAILED DESCRIPTION

[0019] The present disclosure relates to the use of multiple nozzles for depositing materials in additive manufacturing. In particular, the present disclosure relates to devices and techniques for simultaneously depositing material in additive manufacturing from multiple nozzles of a single system to a single object being manufactured. In embodiments, aspects herein can be directed to fused deposition modeling, but need not be limited thereto and can be applied to any other additive manufacturing technique appropriate.

[0020] As used herein, references to "extrude," "print," or other technique-specific additive manufacturing terminology is not intended to be exclusive, and those of skill in the art will appreciate the scope and spirit of the innovation beyond any specific environment described. Specifically, in fused deposition modeling, a filament of the printing material can be extruded, but other techniques can be employed under the disclosures herein.

[0021] Aspects herein relate to nozzles or other additive manufacturing systems depositing, fusing, or otherwise combining printing materials. Where two or more printing materials are described, they can be the same or different in various embodiments. While fused deposition manufacturing and three-dimensional printing are discussed in most embodiments, it is understood that the disclosures herein can be applied to various other technologies related to additive manufacturing. As the claims or other sections may refer to different (e.g., first and second) portions of printed components or products, it is appreciated that these portions may be different layers, different sections, or aspects which are not part of the final product such as support elements which are removed after the product is complete.

[0022] As used herein, "repositionable" means capable of displacement or rotation, and should be construed in a broad, non-limiting manner. "Coupling" generally refers to interaction and some capability to work in tandem. Mechanical coupling places two components in contact, either directly or through intervening hardware. Where elements are "removably coupled," they are connected by attachment means which facilitating install or uninstall avoiding destruction or deformation of either component being attached. "Operative coupling" or "communication" (e.g., fluid communication, electrical communication) refers to components working together, even if such components are not in physical contact (though they may be in physical contact). This also alludes to "electrical coupling," where by two components can transmit electricity or signals between one another.

[0023] As used herein, a positioning structure is a structure for moving at least print heads and nozzles (or similar components) during additive manufacturing. A positioning structure can be or include positionable substructures such as gantry structure/apparatus, crane structure/apparatuses, robot structure/apparatuses, and others described herein. Thus, a positioning structure can be one of the described apparatuses, or a combination thereof, with each individual apparatus defining a positionable substructure.

[0024] Where temperatures are described herein, such as those of print materials, such temperatures can be instantaneous, gradient, or average temperatures of a point, area, or volume.

[0025] An additive manufacturing system is shown in the accompanying drawings with examples of modifications of the system shown in individual figures. It will be understood that the various components and examples in the figures may be combined and interchanged in accordance with the description that follows. In general, the additive manufacturing system includes one or more nozzles that provide material to form an object. The material is provided onto a surface and is built up in passes or layers to form the desired object. To form the object relative movement between the nozzle and the surface are achieved by moving the nozzle or moving the surface to form the desired layering or other patterns required to form the object.

[0026] "Layers" discussed herein describe respective cross sections (or other portions) printed by a nozzle during a given movement of one or more nozzles building an object.

Building a layer with one or more nozzles is described in various techniques as a "scanning pass" or "scan cycle" whereby the nozzles scan over the surface to which the layer will be applied depositing material to fill the space of the layer. These can be completed by one or more nozzles, with additional material built in a next or subsequent layer attached to or operative with the previous layer. In this regard, as used herein, a "first layer" and "second layer" can be any two successive layers, and need not (but can) be the very first and second layer used in construction of an object. As used herein, references to a "subsequent layer" or "next layer" is intended to reference a layer built (or being built) atop or into a "previous layer" or "earlier layer." While alternatives are recognizable based on the disclosures herein, embodiments of systems and methods herein are configured to print a subsequent layer onto an earlier layer while the earlier layer is still printing and before the earlier layer has completely solidified or cooled, thereby permitting greater interlayer commingling or adhesion. This technique is distinct from others whereby multiple nozzles may be used in arrays to expedite printing of a single layer, or to print disparate elements which are not immediately adjacent to another previous layer still being printed during at least a portion of the subsequent layer printing. Further, even in embodiments employing a waiting scheme (described below), at least two nozzles provide material for a first layer and a second layer simultaneously for a portion of the time between waiting periods.

[0027] To produce each layer, at least one actuator is used to create relative movement between material sources and workpieces by moving the nozzle, the surface or both. Any type of actuator may be used including fluid, pneumatic, electrical, mechanical and the like. Several actuator combinations are shown in the accompany figures as examples, but these examples are not limiting. As discussed in more detail below, when moving the nozzle(s), movement may be constrained to a single axis, multiple axes, or the movement may be unconstrained and occur along multiple axes simultaneously. For example, linear motion along a single axis could be achieved with the nozzle mounted on a rail, track, or other guide that constrains its motion to one axis and driven by a suitable actuator along that track. For example, as shown in Figs. 4A and 4B one or more nozzles may be mounted on a nozzle head. The nozzle head may be mounted on a horizontal rail to constrain movement along a horizontal axis. A first actuator may be provided to move the nozzle head along the horizontal rail. Additional degrees of freedom may be added to the system. For example as shown, the rail may be mounted to allow it to move in a vertical plane, for example by providing one or more vertical columns on which the rail may move. A second actuator may be provided to drive the rail to a desired vertical position. Multiple degrees of freedom may be provided with other actuator arrangements including for example, use of a robotic arm or multi-link assembly. Examples of such assemblies are shown in Figs 6A and 6B. As discussed in more detail below, multiple actuator assemblies may be used to move multiple nozzles. For example, individual nozzles may be supported on separate print heads on independent rails (Figs 5A and 5B) or different types of actuators may be combined. Figs. 7A and 7B shown an example where one nozzle is slidably mounted on a rail while another nozzle is provided on a robotic arm that is itself providing on a platform that can move along a track within a work table (or, in alternative embodiments independent of any work table or other mechanically coupled component). Additional actuator types and combinations may be used in accordance with this disclosure and as described in more detail below.

[0028] Providing further detail as to the drawings, FIG. 1 illustrates an example single- nozzle system 100 for three-dimensional printing. Single-nozzle system 100 includes printing subsystem 110 including print head 112 and nozzle 114 which deposits material at deposition site 116. Deposition site 116 is a portion of printed product 170 which is being printed. Printed product 170 includes first layer 172, second layer 178, and third layer 184 each having a layer beginning end 194, 180, 186 and a layer complete end 176, 182, 188. As layers are deposited, temperature gradients exist as the material cools or is re-heated by newly applied heated material (at, e.g., deposition site 116). Accordingly, layers of printed product 170 can include elevated temperature zones 190 and 192.

[0029] In the single-nozzle system 100, material is applied to the printed product 170 being printed by one nozzle 114 developing the cross-section. Adjacent layers 172, 178, 184 are printed sequentially as the nozzle extrudes molten material and moves in the desired path as per the shape of the component to be printed. In this case, second layer 178 (the layer below the current print layer, third layer 184) may have cooled down to a temperature much lower than the temperature of glass transition (Tg) of the material. For instance, when the third layer 184 is being printed, most of the second layer 178 has cooled to a temperature much lower than the glass transition temperature of the material. When the molten material is deposited at deposition site 116 on the (cooled) second layer 178, there will be some local reheat below the newly- applied polymer melt (causing or sustaining, e.g., elevated temperature zone 190), but the relative temperature change may be low. This higher temperature gradient between layers can reduce inter-layer adhesion and related material properties of the printed product 170.

[0030] FIGS. 2A and 2B illustrate an example multiple-nozzle system 200 permitting simultaneous printing of consecutive layers of a printed object 270 on a printer bed 230. Multi- nozzle system 200 includes printing subsystem 210 comprised of first print head 216, second print head 214, and third print head 212, respectively including first print nozzle 222, second print nozzle 220, and third print nozzle 218 depositing printed material at deposition site 228, 226, or 224. Printing of printed object 270 begins at starting end 272 and ends at completion end 274 for at least layers 276, 278, and 280. While described in a two-dimensional sense regarding starting end 272 and completion end 274, it is understood that these bounds exist in three dimensions and that the scope of printed objects developed using system 200 or other systems herein extends to complex shapes with variable cross sections and different from those depicted for purposes of illustration.

[0031] The print heads 216, 214, 212 are shown extended or retracted to different levels to match the height of their respective deposition sites 228, 226, and 224, and can further include actuators for adjustment to such effect. Print heads 216, 214, and 212 and attached nozzles 222, 220, and 218 can follow a printing path 290 which can be constant or variable and common or changing between two or more nozzles and/or layers.

[0032] As shown in FIGS. 2A and 2B, the first nozzle 222 prints the first layer 276, the second nozzle 220 prints the second layer 278, the third nozzle 218 prints the third layer 280, et cetera, simultaneously extruding material to print the component more rapidly than with a single nozzle. Once complete, the first nozzle 222 can print a fourth layer, the second nozzle 220 a fifth layer, and so forth, or the nozzles can be re-ordered to perform other successive printing.

[0033] As introduced above, while aspects herein generally show and describe substantially symmetrical layers, it is understood that layers can vary and that nozzles can print only part of the time for a given layer, or define new shapes and arrangements, without departing from the scope and spirit of the innovation. For example, a hollow sphere could be constructed with nozzles scanning a rectangular area printing during only portions of the scan time, or moving in a contour-pattern around circular (or ringed) cross-sections. In the first example, the nozzles may move in linear patterns and deposit only when crossing the boundaries of the sphere's walls, with subsequent nozzles building different layers in rapid succession through the production of two or more simultaneously-built layers of spherical wall. In the second example, nozzles can track one another around the circular path to build layers simultaneously while continuously depositing material. Other schemes will be appreciated in view of the disclosures herein and different products or objects to be printed.

[0034] FIG. 3 illustrates an example multiple-nozzle system 300 in a manner identifying material heat constraints and permitting improvement over single nozzle systems based on printing material temperature. Multiple-nozzle system 300 includes printing subsystem 310 comprised of first print head 316, second print head 314, and third print head 312, respectively coupled with first nozzle 322 depositing material at first deposition site 328, second nozzle 320 depositing material at second deposition site 326, and third nozzle 318 depositing material at third deposition site 324. Printed object 370 includes first layer 372, second layer 374, and third layer 376, but these layers may become indistinguishable through material commingling based on interlayer adhesion enabled by the timely succession between nozzles and layer development.

[0035] Using three simultaneously acting nozzles 322, 320, 318 provide for heated material in adjacent layers 372, 374, 376 being concurrently printed. By arranging sequencing of the nozzles, the region below a melt pool (e.g., at or around deposition sites 328, 326, 324) can be above or near the glass transition temperature of the material. As a result, inter-layer adhesion (and/or fusion of the individual elements of printed material) can be improved thereby improving mechanical performance of the completed printed component.

[0036] Such sequencing can be programmed in advance according to printed component plans, printing material characteristics, or other predetermined variables.

Alternatively, print sequencing (e.g., the speed, location, and timing of nozzles and their extrusion of printing material) can be based on realtime-measured variables such as

measurements or estimations regarding temperature gradients or point temperatures. In this fashion, sequencing can be modified in stride to ensure inter-layer adhesion and other print qualities regardless of environment or variable performance.

[0037] FIGS. 4A and 4B illustrate an example embodiment of a multiple-nozzle three- dimensional printing system 400 including printing subsystem 410 having multiple nozzles 418, 420, 422 on a fixed (relative to one another) print heads 412, 414, 416 which are driven together by a carriage 460. All nozzles (e.g., in the illustrated embodiment, nozzles 418, 420, 422) and heads (e.g., in the illustrated embodiment, heads 412, 414, 416) move simultaneously with the carriage 460 while still permitting system 400 to print up to three layers 472, 474, 476 of printed product 470 at once. Carriage 460 can include drive 458, which can move the carriage along horizontal support member 456, and, in embodiments, rotate carriage 460 about horizontal support member 456.

[0038] Printed product 470 is printed on printer bed 430 which in turn rests on system base 450. System base 450 includes tracks 452 allowing carriage 460 to move in at least one linear direction through its connection to movable upright support 454. Movable upright support 454 couples with horizontal support member 456. In embodiments, horizontal support member 456 can move toward or away from printer bed 430 by moving up and down movable upright support 454 (e.g., using one or more elevators).

[0039] In alternative embodiments, the distance between and orientation of the nozzles 418, 420, and 422 with respect to one another can be fixed or variable. In fixed embodiments, the nozzles 418, 420, and 422 can be arranged at positions offset by material layer thickness with respect to one another. In embodiments, heads 412, 414, 416 can be fixed with nozzles 418, 420, 422 moving in one or more dimension (e.g., extending or retracting). Material fed to nozzles 418, 420, and 422 can be fed using feed lines 468, 464, and 462, respectively. Rotary degrees of freedom for one or more nozzles can be provided in embodiments to improve printing of angular or circular tool paths. In this manner, deposition sites 424, 426, and 428 can be reached during movement of at least carriage 460.

[0040] In FIGS. 4A, 4B, and others, various actuating components can also be provided. For example, motors or other actuators driving movable upright supports in tracks, driving horizontal supports up and down movable upright supports, and/or carriages along or around horizontal supports can be provided in single or plural arrangements to effect the results of arrangements and techniques described herein.

[0041] FIGS. 5 A and 5B illustrate an example embodiment of a multiple-nozzle three- dimensional printing system 500 including multiple nozzles 518, 520, 522 on multiple print heads 512, 514, 516 driven by carriages 582, 584, 586. In this fashion, heads 512, 514, 516 can move independently providing variability between nozzle position only limited by the carriages 582, 584, 586 and printer bed 530. Each of carriages 582, 584, and 586 can have separate feed lines 588, 590, and 592 for providing material to respective nozzles for deposition. System 500 is shown producing printed product 570 in the embodiment depicted.

[0042] FIGS. 5A and 5B show nested gantry systems having tracks 552, 556, 560 of different widths in system base 550. In an embodiment, movable upright members 554, 558, 562 can be displaceable along or in tracks 552, 556, 560 or permit vertical movement of carriages 582, 584, 586 by raising or lowering horizontal support members 564, 566, 568 to permit reordering of individual gantry sub-assemblies with respect to the printer bed 530 whereby smaller or larger gantry sub assembly may pass around/over or through/under others. In this fashion, sequencing of nozzles 518, 520, 522 and printing can be varied to accelerate printing, print complex products, and/or continue efficient printing if a nozzle is removed from production (e.g., out of filament, clogged nozzle, improper material). In alternative or complementary embodiments, a fourth track outside track 560 can be connected with tracks 560, 556, and 552 for use with collapsible horizontal rods (e.g., alternative embodiments of horizontal rods 568, 566, and 564) and pairs of collapsible vertical rods (e.g., alternative embodiments of vertical rods 562, 558, and 554) to facilitate movement around other components such as nozzles engaged in printing. In this way, nozzles which have completed layers can change order to move ahead of or behind other nozzles still engaged in printing.

[0043] FIGS. 6A and 6B illustrate another embodiment of a multiple-nozzle system 600 including multiple nozzles 628, 648 on independent robotic arms of robot system 610 for printing printed item 670. A first arm includes arm base 612, pivots 614, 618, 622, and links 616, 620, 624 with the end effector realized as print head 626 and nozzle 628. Similarly, a second arm 630 includes arm base 632, pivots 634, 638, 642, and links 636, 640, 644 with the end effector realized as print head 646 and nozzle 648. Thus, as illustrated, the robotic arms have three links each; but the number of links can increase or decrease depending on the application and freedom required. Also in the illustrated embodiment, the arm bases 612, 630 of each robotic arm is shown to be capable of both rotation and displacement (e.g., at least in track 662 of system base 660, but the arm bases 612, 630 may be independently movable without a track in alternative embodiments). This allows each arm to reach any region of the printer bed 650 without interfering with other robotic arms. As will be appreciated, alternative robotic arms (e.g., without linear motion capability) can be employed without departing from the scope or spirit of the innovation.

[0044] FIGS. 7A and 7B illustrate still another embodiment of a multiple-nozzle three- dimensional printing system 700 having print heads 726 and 740 positioned by both carriage system 730 and robot system 710 to produce printed product 770. The robot system 710 includes arm base 712, pivots 714, 718, and 722, links 716, 720, 724, and provides an end effector with print head 726 and nozzle 728. Carriage 738, described further below, is mechanically coupled to at least print head 740 and nozzle 742. Systems similar to those provided above can be provided in various combinations (e.g., one or more robot arms, one or more carriages, one or more nozzles per head) to create hybrid systems tailored to specific environments or build constraints. [0045] In system 700, system base 750 supports printer bed 760 and includes track 752. As shown, carriage system 730 includes gantry bases 732 with movable upright members 734 attached thereto carrying horizontal support member 736. Horizontal support member 736 can be supported by one or more elevators 754 capable of raising and lowering this subassembly on movable upright members 734. Carriage 738 can also move along horizontal support member 736 using one or more actuators of carriage 738 or associated components.

[0046] In an embodiment, horizontal support member 736 can collapse and/or pass through one or both of the elevators 754 (e.g., extending out one or both sides) to reduce the dimension between the movable upright members 734, thereby being capable of negotiating nonlinear portions of track 752 inasmuch as the distance between upright members 734 can be reduced (or increased to the maximum or fully extended length of horizontal support member 736) to accommodate portions where opposite sides of track 752 are separated by varying dimensions.

[0047] As indicated above, print sequencing can be provided according to printer materials, component properties, and other variables. In further aspects, sequencing can be structured according to systems having two or more subsystems for moving print heads (e.g., two or more total carriages and/or robot arms) to enforce non-collision/non-interference

requirements. FIG. 8 illustrates a methodology 800 for producing a linear multi-layer printed component employing a waiting sequencing process whereby nozzles are subject to a

predetermined delay before advancing to prevent interference. At 810, a first nozzle begins printing while the next two nozzles wait for the first nozzle to advance sufficiently. At 820, the second nozzle begins printing, and at 830, the third nozzle proceeds.

[0048] FIG. 9 shows further details on a methodology 900 for printing according to a "with waiting" sequencing scheme. Methodology 900 shows first, second, and third nozzles printing layers sequentially. At 910, the first nozzle finishes a first layer, then at 920 proceeds (or returns to) the start of a fourth layer to follow the third layer still under construction. The advancement of the second and third nozzles - and the first in fourth or subsequent layers - can be offset by a constant or variable time or distance before each nozzle begins printing its layer in process. After a layer is complete, the nozzle which has ceased production of its respective layer can be made to wait until all subsequent layers are complete, establishing discrete linear or circular cycles of operation. Thus, at 930, the first nozzle starts a fourth layer while the second and third nozzles wait, and then at 940 the second nozzle begins printing a fifth layer while the third nozzle awaits its sequenced time to print the sixth layer. Aspect 950 of methodology 900 explains how this waiting sequence can continue into additional layers.

[0049] FIG. 10 illustrates an embodiment of a methodology 1000 for a multi-nozzle three-dimensional printing system which uses an alternative "without waiting" print sequencing scheme. Here, cycles of operation are continuous, and a first nozzle can begin applying its subsequent layer (a fourth total layer) before the last nozzle to begin (or any other nozzle such as where subsequent layers are being printed onto previously printed layers) is complete with its layer (e.g., third nozzle applying third layer). In this fashion, the only wait time is imposed at the beginning of production to permit sufficient offset to avoid collisions between nozzles. FIG. 10 may be implemented in embodiments by, e.g., multi-nozzle three-dimensional printing systems having multiple robotic arms, carriage systems, or combinations of robotic arms and carriage systems.

[0050] Thus, methodology 1000 begins at 1010 with a first nozzle having finished a first layer while second and third nozzles print second and third layers. At 1020, the first nozzle begins printing a fourth layer atop the partially-complete third (and second) layer(s) while the other two nozzles are still printing the second and third layers. At 1030, the second nozzle begins printing a fifth layer atop the under-construction fourth layer, and at 1040 a sixth layer is in production with the other two nozzles working when the third nozzle starts depositing printed material at the beginning of its next layer. Aspect 1050 of methodology 1000 explains how this continuous sequence can continue into additional layers.

[0051] While the technique illustrated shows all nozzles following common path(s), it is understood that nozzles following distinct paths (e.g., by layer or according to special deposition patterns) is embraced by the scope and spirit of the innovation. Layers can take any shape involving horizontal or vertical dimensions at any angle or curvature. Further, while the example provided in FIGS. 9 and 10 (and other figures) shows a three-nozzle configuration, alternatives having more or fewer nozzles are captured under the disclosures herein. Base 1170 can be printed using the same system or transferred from another system prior to being used. Such arrangements for creation of base 1170 could use single or multiple nozzle printing and/or employ other techniques such as those employing extruded sheets, injection molded components, and so forth. [0052] FIG. 11 illustrates an example embodiment of a multi-nozzle printing system 1100 capable of simultaneously printing different features of a product. System 1100 includes first nozzle subassembly 1110, second nozzle subassembly 1120, and third nozzle subassembly 1130, which are respectively printing printed features 1172, 1174, and 1176 of printed product 1170. Printed product 1170 is printed atop printer bed 1150 which is supported by system base 1140. As shown in FIG. 11, independent nozzles completed printing of a wide base of the product on a printing table, and as depicted are engaged in independently developing distinctive features of the printed product. In embodiments, two or more nozzles can be allocated to a single feature, and/or the nozzles can re-combine to develop additional features or elements (e.g., additional projecting features, a new wide layer connecting projecting features).

[0053] The significance of using multiple nozzles can be appreciated in view of time saved as depicted in, e.g., the graph 1200 of FIG. 12. This shows the time required to print a 100-layer part, based on assumptions regarding the time to print a layer and lag time between nozzles. If a layer takes one hour to print, current single- nozzle systems require at least 100 hours to complete printing. However, multiple nozzle systems described above provide for dramatic time savings in both "with waiting" (plot of Scheme 1) and "without waiting" (Scheme 2) sequencing schemes. As shown, Scheme 1 immediately saves time by simultaneously printing layers for each nozzle, then pausing to await completion of all in-process layers before the first nozzle is re-utilized. Scheme 2 saves additional time by re-introducing nozzles before all layers in process are completed, removing the partial downtime encountered in discrete cycles of all nozzles. Thus, for an example three nozzle system, a waiting scheme saves nearly fifty- five percent of the production time compared to single nozzle systems, and a without waiting scheme saves nearly sixty-six percent.

[0054] Multiple-nozzle systems can also be employed to perform three-dimensional printing not enabled by single-nozzle systems. For example, one or more nozzles can print a component material while an additional nozzle prints a removable support material providing structural bracing for overhanging or otherwise initially-unstable portions of the component. In another example, a first nozzle can print a neat material (e.g., a polycarbonate), a second nozzle can print a composite material (e.g., a polycarbonate with 10% glass fibers which is stiffer than the material of the first nozzle), and a third nozzle can print a different composite material (e.g., a polycarbonate with 20% glass fibers which is stiffer than the material of the second nozzle), facilitating production of graded parts with varying fiber content throughout based on performance requirements. Different nozzles using different materials can carry substrate materials, conductive materials, electrostatic discharge materials, and others. While the foregoing suggests various options, nothing herein should be interpreted as limiting printing the same material from two or more nozzles simultaneously or successively to expedite printing of a unitary piece made of a single material.

[0055] Other production variations can be accomplished using multi-nozzle systems as well. For example, the integration of robotic arms with other tools such as milling heads, laser cutting apparatuses, pick and placement robotic arm ends, and others can be used along with the multi-nozzle systems to combine multiple processes. In a non-limiting example, a pick and place robotic arm can be used with an insert (e.g., pre-manufactured such as a composite laminate, metal plate) to place the insert at an appropriate location on or above the printer bed during printing.

[0056] It should be appreciated that the present disclosure can include any one up to all of the following examples:

[0057] Example 1. A three-dimensional printing system, comprising:

a first printing nozzle causing a first printing material to build at least a first portion of a printed component;

a second printing nozzle causing a second printing material to build at least a second portion of the printed component, wherein the second printing nozzle causes the second printing material to build at least the second portion of the printed component during at least a portion of time when the first printing nozzle causes the first printing material to build at least the first portion of the printed component;

a positioning structure configured to position at least the first printing nozzle and the second printing nozzle during production of the printed component; and

a print controller configured to control at least the positioning structure during production of the printed component.

[0058] Example 2. The three-dimensional printing system of Example 1 , wherein the second portion of the printed component is a subsequent layer and the first portion of the printed component is an earlier layer. [0059] Example 3. The three-dimensional printing system of any of Examples 1-2, further comprising a multi-nozzle head coupled with at least the first printing nozzle, the second printing nozzle, and the positioning structure.

[0060] Example 4. The three-dimensional printing system of Example 3, wherein at least one of the first printing nozzle and the second printing nozzle is repositionable on the multi- nozzle head.

[0061] Example 5. The three-dimensional printing system of Example 4, wherein the at least one of the first printing nozzle and the second printing nozzle is controlled by the print controller.

[0062] Example 6. The three-dimensional printing system of any of Examples 1-5, further comprising:

a first positionable substructure mechanically coupled with at least the first printing nozzle and operatively coupled with the print controller; and

a second positionable substructure mechanically coupled with at least the second printing nozzle and operatively coupled with the print controller.

[0063] Example 7. The three dimensional printing system of Example 6, wherein at least one of the first positionable substructure and the second positionable substructure is a gantry structure.

[0064] Example 8. The three dimensional printing system of Example 6, wherein at least one of the first positionable substructure and the second positionable substructure is a robotic structure.

[0065] Example 9. The three dimensional printing system of Example 6, wherein the print controller sequences at least the first positionable substructure and the second positionable substructure to avoid interference.

[0066] Example 10. The three dimensional printing system of any of Examples 1-9, wherein the print controller sequences at least the first printing nozzle and the second printing nozzle according to a material temperature.

[0067] Example 11. The three dimensional printing system of any of Examples 1-10, wherein the controller instructs the positioning structure to position at least one of the first nozzle and the second nozzle to build removable bracing for the printed component.

[0068] Example 12. A method, comprising: printing from a first printed material at least a first portion of a printed component using a first nozzle; and

printing from a second printed material at least a second portion of the printed component using a second nozzle simultaneously with printing of at least the first portion of the printed component.

[0069] Example 13. The method of Example 12, wherein at least the second portion of the printed component is a subsequent layer and at least the first portion of the printed component is an earlier layer.

[0070] Example 14. The method of any of Examples 12-13, further comprising:

moving the first nozzle while printing the first portion of the printed component using a positioning structure; and

moving the second nozzle while printing the second portion of the printed component using the positioning structure.

[0071] Example 15. The method of Example 12, wherein a positioning structure moves a multi-nozzle head mechanically coupled with at least the first nozzle and the second nozzle.

[0072] Example 16. The method of Example 15, further comprising repositioning at least one of the first nozzle and the second nozzle with respect to the multi-nozzle head.

[0073] Example 17. The method of Example 15, wherein the positioning structure includes a first positionable substructure that independently positions the first nozzle and a second positionable substructure that independently positions the second nozzle.

[0074] Example 18. The method of Example 17, further comprising solving a movement sequence for at least one of the first positionable substructure and the second positionable substructure.

[0075] Example 19. The method of Example 18, wherein the movement sequence is solved to avoid interference between at least the first nozzle and its first positionable substructure and the second nozzle and its second positionable substructure.

[0076] Example 20. The method of Example 19, wherein the movement sequence is solved according to a material temperature.

[0077] Example 21. A three-dimensional printing system, consisting essentially of: a first printing nozzle causing a first printing material to build at least a first portion of a printed component; a second printing nozzle causing a second printing material to build at least a second portion of the printed component, wherein the second printing nozzle causes the second printing material to build at least the second portion of the printed component during at least a portion of time when the first printing nozzle causes the first printing material to build at least the first portion of the printed component;

[0078] Example 22. The three-dimensional printing system of Example 21, wherein the second portion of the printed component is a subsequent layer and the first portion of the printed component is an earlier layer.

[0079] Example 23. The three-dimensional printing system of any of Examples 21-22, further consisting essentially of a multi-nozzle head coupled with at least the first printing nozzle, the second printing nozzle, and the positioning structure.

[0080] Example 24. The three-dimensional printing system of Example 23, wherein at least one of the first printing nozzle and the second printing nozzle is repositionable on the multi- nozzle head.

[0081] Example 25. The three-dimensional printing system of Example 24, wherein the at least one of the first printing nozzle and the second printing nozzle is controlled by the print controller.

[0082] Example 26. The three-dimensional printing system of any of Examples 21-25, further consisting essentially of:

[0083] Example 27. The three dimensional printing system of Example 26, wherein at least one of the first positionable substructure and the second positionable substructure is a gantry structure. [0084] Example 28. The three dimensional printing system of Example 26, wherein at least one of the first positionable substructure and the second positionable substructure is a robotic structure.

[0085] Example 29. The three dimensional printing system of Example 26, wherein the print controller sequences at least the first positionable substructure and the second positionable substructure to avoid interference.

[0086] Example 30. The three dimensional printing system of any of Examples 21-29, wherein the print controller sequences at least the first printing nozzle and the second printing nozzle according to a material temperature.

[0087] Example 31. The three dimensional printing system of any of Examples 21-30, wherein the controller instructs the positioning structure to position at least one of the first nozzle and the second nozzle to build removable bracing for the printed component.

[0088] Example 32. A method, consisting essentially of:

printing from a first printed material at least a first portion of a printed component using a first nozzle; and

[0089] Example 33. The method of Example 32, wherein at least the second portion of the printed component is a subsequent layer and at least the first portion of the printed component is an earlier layer.

[0090] Example 34. The method of any of Examples 32-33, further consisting essentially of:

[0091] Example 35. The method of Example 32, wherein a positioning structure moves a multi-nozzle head mechanically coupled with at least the first nozzle and the second nozzle. [0092] Example 36. The method of Example 35, further consisting essentially of repositioning at least one of the first nozzle and the second nozzle with respect to the multi- nozzle head.

[0093] Example 37. The method of Example 35, wherein the positioning structure includes a first positionable substructure that independently positions the first nozzle and a second positionable substructure that independently positions the second nozzle.

[0094] Example 38. The method of Example 37, further consisting essentially of solving a movement sequence for at least one of the first positionable substructure and the second positionable substructure.

[0095] Example 39. The method of Example 38, wherein the movement sequence is solved to avoid interference between at least the first nozzle and its first positionable substructure and the second nozzle and its second positionable substructure.

[0096] Example 40. The method of Example 39, wherein the movement sequence is solved according to a material temperature.

[0097] Example 41. The method of Example 20, wherein the material temperature is calculated for inter-layer adhesion.

[0098] Example 42. The method of Example 20, wherein the material temperature is calculated for manufacturing speed.

[0099] Example 43. The method of Example 12, further comprising manufacturing a base onto which the printed component is printed.

[00100] Example 44. The method of Example 43, wherein the base is manufactured by three-dimensional printing.

[00101] Example 45. The method of Example 43, wherein the base is manufactured by an alternate manufacturing technique not including three-dimensional printing.

[00102] Example 46. The method of Example 12, wherein the first nozzle is located on a multi-nozzle print head and the second nozzle is located on a single-nozzle print head.

[00103] Example 47. The method of Example 40, wherein the material temperature is calculated for inter-layer adhesion.

[00104] Example 48. The method of Example 40, wherein the material temperature is calculated for manufacturing speed. [00105] Example 49. The method of Example 32, further consisting essentially of manufacturing a base onto which the printed component is printed.

[00106] Example 50. The method of Example 49, wherein the base is manufactured by three-dimensional printing.

[00107] Example 51. The method of Example 49, wherein the base is manufactured by an alternate manufacturing technique not including three-dimensional printing.

[00108] Example 52. The method of Example 32, wherein the first nozzle is located on a multi-nozzle print head and the second nozzle is located on a single-nozzle print head.

[00109] It is to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term "comprising" can include the embodiments "consisting of and "consisting essentially of." Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

[00110] As discussed, various aspects disclosed herein provide at least the use of multiple nozzles to print adjacent layers simultaneously in additive manufacturing; sequencing methodologies that enables printing adjacent layers simultaneously; the use of multiple nozzles in a range of printing methodologies such as gantry-based single and multiple head systems, robotic systems, and combinations thereof; improvement in mechanical performance through sequencing in comparison to single-nozzle printing solutions; simultaneous printing of support and part materials using multiple nozzles and sequencing techniques; efficient printing of multiple material types; and combinations of multiple print nozzles/heads with robotic arms and other accessories such as pick and place arms, laser cutting attachments, and others.

Claims

What is claimed is:

1. A three-dimensional printing system, comprising:

2. The three-dimensional printing system of claim 1, wherein the second portion of the printed component is a subsequent layer and the first portion of the printed component is an earlier layer.

3. The three-dimensional printing system of any of claims 1-2, further comprising a multi- nozzle head coupled with at least the first printing nozzle, the second printing nozzle, and the positioning structure.

4. The three-dimensional printing system of claim 3, wherein at least one of the first printing nozzle and the second printing nozzle is repositionable on the multi-nozzle head.

5. The three-dimensional printing system of claim 4, wherein the at least one of the first printing nozzle and the second printing nozzle is controlled by the print controller.

6. The three-dimensional printing system of any of claims 1-5, further comprising: a first positionable substructure mechanically coupled with at least the first printing nozzle and operatively coupled with the print controller; and

7. The three dimensional printing system of claim 6, wherein at least one of the first positionable substructure and the second positionable substructure is a gantry structure.

8. The three dimensional printing system of claim 6, wherein at least one of the first positionable substructure and the second positionable substructure is a robotic structure.

9. The three dimensional printing system of claim 6, wherein the print controller sequences at least the first positionable substructure and the second positionable substructure to avoid interference.

10. The three dimensional printing system of any of claims 1 -9, wherein the print controller sequences at least the first printing nozzle and the second printing nozzle according to a material temperature.

11. The three dimensional printing system of any of claims 1-10, wherein the controller instructs the positioning structure to position at least one of the first nozzle and the second nozzle to build removable bracing for the printed component.

12. A method, comprising:

13. The method of claim 12, wherein at least the second portion of the printed component is a subsequent layer and at least the first portion of the printed component is an earlier layer.

14. The method of any of claims 12-13, further comprising:

15. The method of claim 12, wherein a positioning structure moves a multi-nozzle head mechanically coupled with at least the first nozzle and the second nozzle.

16. The method of claim 15, further comprising repositioning at least one of the first nozzle and the second nozzle with respect to the multi-nozzle head.

17. The method of claim 15, wherein the positioning structure includes a first positionable substructure that independently positions the first nozzle and a second positionable substructure that independently positions the second nozzle.

18. The method of claim 17, further comprising solving a movement sequence for at least one of the first positionable substructure and the second positionable substructure.

19. The method of claim 18, wherein the movement sequence is solved to avoid interference between at least the first nozzle and its first positionable substructure and the second nozzle and its second positionable substructure.

20. The method of claim 19, wherein the movement sequence is solved according to a material temperature.