U.S. patent application number 15/217385 was filed with the patent office on 2017-02-23 for system and method to control a three-dimensional (3d) printer.
The applicant listed for this patent is Voxel8, Inc.. Invention is credited to Travis Busbee, Max Eskin, John Minardi, Jonathan Tran.
Application Number | 20170050388 15/217385 |
Document ID | / |
Family ID | 58157351 |
Filed Date | 2017-02-23 |
United States Patent
Application |
20170050388 |
Kind Code |
A1 |
Minardi; John ; et
al. |
February 23, 2017 |
SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER
Abstract
A three-dimensional (3D) printer device includes a first
extruder configured to deposit a material on a deposition platform,
an actuator coupled to at least one of the first extruder or the
deposition platform, and a controller coupled to the actuator. The
controller is configured to cause the first extruder to deposit a
first portion of the material corresponding to a first portion of a
physical model. The controller may be configured to cause the first
extruder to be cleaned, purged, or both, after the first extruder
deposits the first portion of the material. The controller may be
configured to cause the first extruder to deposit a second portion
of the material after the first extruder is cleaned. The second
portion of the material corresponds to a second portion of the
physical model.
Inventors: |
Minardi; John; (Somerville,
MA) ; Busbee; Travis; (Somerville, MA) ; Tran;
Jonathan; (Somerville, MA) ; Eskin; Max;
(Somerville, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Voxel8, Inc. |
Somerville |
MA |
US |
|
|
Family ID: |
58157351 |
Appl. No.: |
15/217385 |
Filed: |
July 22, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62208222 |
Aug 21, 2015 |
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|
62340389 |
May 23, 2016 |
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62340421 |
May 23, 2016 |
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62340453 |
May 23, 2016 |
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62340436 |
May 23, 2016 |
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62340432 |
May 23, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B33Y 50/02 20141201;
B29B 7/74 20130101; G05B 19/4099 20130101; B29B 7/72 20130101; G05B
2219/49007 20130101; Y02P 90/265 20151101; B29C 64/35 20170801;
B29C 64/393 20170801; B29C 64/106 20170801; B29C 64/124 20170801;
G05B 2219/35134 20130101; B33Y 30/00 20141201; B29C 64/118
20170801; B33Y 10/00 20141201 |
International
Class: |
B29C 67/00 20060101
B29C067/00; B29B 7/72 20060101 B29B007/72; B33Y 50/02 20060101
B33Y050/02; B33Y 10/00 20060101 B33Y010/00; B33Y 30/00 20060101
B33Y030/00 |
Claims
1. A three-dimensional (3D) printer device comprising: a first
extruder configured to deposit a material on a deposition platform;
an actuator coupled to at least one of the first extruder or the
deposition platform; and a controller coupled to the actuator, the
controller configured to cause the first extruder to deposit a
first portion of the material corresponding to a first portion of a
physical model, to cause the first extruder to be cleaned, purged,
or both, after the first extruder deposits the first portion of the
material, and to cause the first extruder to deposit a second
portion of the material after the first extruder is cleaned,
purged, or both, the second portion of the material corresponding
to a second portion of the physical model.
2. The 3D printer device of claim 1, further comprising a memory to
store data representing a set of commands, wherein the controller
is configured to execute commands of the set of commands to form
the physical model.
3. The 3D printer device of claim 1, further comprising a
communication interface to receive commands from a computing
device, wherein the controller is configured to execute the
commands to form the physical model.
4. The 3D printer device of claim 1, further comprising a timer,
wherein the controller causes the first extruder to be cleaned,
purged, or both, based on the timer satisfying a threshold.
5. The 3D printer device of claim 4, wherein the timer is
configured to track time elapsed during deposition of the first
portion of the material.
6. The 3D printer device of claim 1, further comprising a material
counter configured to track a quantity of the material deposited to
form the first portion of the physical model, wherein the
controller causes the first extruder to be cleaned, purged, or
both, based on a value of the material counter satisfying a
threshold.
7. The 3D printer device of claim 1, further comprising a second
extruder configured to deposit a second material on the deposition
platform.
8. The 3D printer device of claim 7, further comprising a timer
associated with the second extruder, wherein the controller causes
the first extruder to be cleaned, purged, or both, based on the
timer satisfying a threshold.
9. The 3D printer device of claim 8, wherein the timer tracks time
since the second extruder was used to deposit the second
material.
10. The 3D printer device of claim 8, further comprising: a first
container configured to store a first component of the second
material; a second container configured to store a second component
of the second material; and a mixer configured to mix the first
component and the second component to form the second material.
11. The 3D printer device of claim 10, wherein the timer tracks
time since mixing the first component and the second component,
wherein the controller causes the first extruder to be cleaned,
purged, or both, based on the time since mixing satisfying a
threshold.
12. The 3D printer device of claim 10, wherein the first component
includes a resin and the second component includes a hardening
agent.
13. The 3D printer device of claim 7, wherein the controller is
configured to cause the second extruder to be cleaned, purged, or
both, based on the first extruder being cleaned, purged, or
both.
14. The 3D printer device of claim 7, wherein the first extruder
comprises filament-feed extruder and the second extruder comprises
a paste extruder.
15. The 3D printer device of claim 7, wherein the second extruder
comprises filament-feed extruder and the first extruder comprises a
paste extruder.
16. The 3D printer device of claim 7, wherein the controller is
configured to cause the second extruder to deposit a portion of the
second material after the first extruder deposits the first portion
of the material and before the first extruder deposits the second
portion of the material, wherein the second material is chemically
distinct from the material.
17. A three-dimensional (3D) printer device comprising: a first
extruder configured to deposit a first material on a deposition
platform; a second extruder configured to deposit a second material
on the deposition platform; an actuator coupled to the first
extruder, the second extruder, the deposition platform, or a
combination thereof; and a controller coupled to the actuator, the
controller configured to cause the first extruder to deposit a
first portion of the first material corresponding to a first
portion of a physical model and to cause the second extruder to be
cleaned, purged, or both, after the first extruder deposits the
first portion of the first material.
18. The 3D printer device of claim 17, further comprising a memory
to store data representing a set of commands, wherein the
controller is configured to execute commands of the set of commands
to form the physical model.
19. The 3D printer device of claim 17, further comprising a
communication interface to receive commands from a computing
device, wherein the controller is configured to execute the
commands to form the physical model.
20. The 3D printer device of claim 17, further comprising a
material counter configured to track a quantity of the first
material deposited to form the first portion of the physical model,
wherein the controller causes the second extruder to be cleaned,
purged, or both, based on a value of the material counter
satisfying a threshold.
21. The 3D printer device of claim 17, further comprising a timer,
wherein the controller causes the second extruder to be cleaned,
purged, or both, based on the timer satisfying a threshold.
22. The 3D printer device of claim 21, wherein the timer is
configured to track time elapsed during deposition of the first
portion of the first material.
23. The 3D printer device of claim 21, wherein the timer tracks
time since the second extruder was used to deposit the second
material.
24. The 3D printer device of claim 21, further comprising: a first
container configured to store a first component of the second
material; a second container configured to store a second component
of the second material; and a mixer configured to mix the first
component and the second component to form the second material.
25. The 3D printer device of claim 24, wherein the timer tracks
time since mixing the first component and the second component,
wherein the controller causes the second extruder to be cleaned,
purged, or both, based on the time since mixing satisfying a
threshold.
26. The 3D printer device of claim 24, wherein the first component
include a resin and the second component includes a hardening
agent.
27. The 3D printer device of claim 17, wherein the controller is
configured to cause the first extruder to be cleaned, purged, or
both, based on the second extruder being cleaned.
28. The 3D printer device of claim 17, wherein the first extruder
comprises filament-feed extruder and the second extruder comprises
a paste extruder.
29. The 3D printer device of claim 17, wherein the second extruder
comprises filament-feed extruder and the first extruder comprises a
paste extruder.
30. The 3D printer device of claim 17, wherein the controller is
configured to cause the second extruder to deposit a portion of the
second material after the first extruder deposits the portion of
the first material.
31. The 3D printer device of claim 17, wherein the controller is
configured to perform a test print using the first extruder and the
second extruder to calibrate relative positions of the first
extruder and the second extruder.
32. A method comprising: depositing, using a first extruder of a
three-dimensional (3D) printer device, a first portion of a first
material corresponding to a first portion of a physical model of an
object; after depositing the first portion of the first material,
cleaning the first extruder, purging the first extruder, or
cleaning and purging the first extruder; and after cleaning the
first extruder, purging the first extruder, or cleaning and purging
the first extruder, depositing, using the first extruder, a second
portion of the first material, the second portion of the first
material corresponding to a second portion of the physical
model.
33. The method of claim 32, further comprising storing data
representing a set of commands to form the physical model at a
memory of the 3D printer device.
34. The method of claim 32, further comprising receiving data
representing a set of commands to form the physical model via a
communication interface of the 3D printer device.
35. The method of claim 32, further comprising tracking a quantity
of the first material deposited to form the first portion of the
physical model, wherein the first extruder is cleaned, purged, or
both, based on the quantity of the first material deposited
satisfying a threshold.
36. The method of claim 32, further comprising tracking a
deposition time associated with forming the first portion of the
physical model, wherein the first extruder is cleaned, purged, or
both, based on the deposition time satisfying a threshold.
37. The method of claim 32, further comprising tracking downtime of
a second extruder of the 3D printer device, wherein the first
extruder is cleaned, purged, or both, based on the downtime of the
second extruder satisfying a threshold.
38. The method of claim 32, further comprising: mixing two or more
components to form the first material; and tracking a time since
mixing, wherein the first extruder is cleaned, purged, or both,
based on the time since mixing satisfying a threshold.
39. The method of claim 38, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
40. The method of claim 38, wherein mixing the two or more
components includes: dispensing a resin from a first container of
the 3D printer device into a mixer of the 3D printer device;
dispensing a hardening agent from a second container of the 3D
printer device into the mixer; and mixing the resin and the
hardening agent in the mixer, wherein the mixer is in fluid
communication with the first extruder.
41. The method of claim 32, further comprising: mixing two or more
components to form a second material associated with a second
extruder of the 3D printer device; and tracking a time since
mixing, wherein the first extruder is cleaned, purged, or both,
based on the time since mixing satisfying a threshold.
42. The method of claim 41, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
43. The method of claim 41, further comprising cleaning the second
extruder after depositing the first portion of the first material
and before depositing the second portion of the first material.
44. The method of claim 41, wherein the first extruder comprises
filament-feed extruder and the second extruder comprises a paste
extruder.
45. The method of claim 32, further comprising, after depositing
the first portion of the first material and before depositing the
second portion of the first material depositing a second material,
using a second extruder of the 3D printer device, wherein the
second material is chemically distinct from the first material.
46. The method of claim 32, further comprising, after depositing
the first portion of the first material and before depositing the
second portion of the first material, cleaning a second extruder,
purging the second extruder, or cleaning and purging the second
extruder.
47. A method comprising: depositing, using a first extruder of a
three-dimensional (3D) printer device, a portion of a first
material to form a first portion of a physical model; and after
depositing the portion of the first material, cleaning a second
extruder of the 3D printer device, purging the second extruder, or
cleaning and purging the second extruder.
48. The method of claim 47, further comprising storing data
representing a set of commands to form the physical model at a
memory of the 3D printer device.
49. The method of claim 47, further comprising receiving data
representing a set of commands to form the physical model via a
communication interface of the 3D printer device.
50. The method of claim 47, further comprising tracking a quantity
of the first material deposited to form the first portion of the
physical model, wherein the second extruder is cleaned, purged, or
both, based on the quantity of the first material deposited
satisfying a threshold.
51. The method of claim 47, further comprising tracking a
deposition time associated with forming the first portion of the
physical model, wherein the second extruder is cleaned, purged, or
both, based on the deposition time satisfying a threshold.
52. The method of claim 47, further comprising tracking downtime of
the second extruder, wherein the second extruder is cleaned,
purged, or both, based on the downtime of the second extruder
satisfying a threshold.
53. The method of claim 47, further comprising: mixing two or more
components to form the first material; and tracking a time since
mixing, wherein the second extruder is cleaned, purged, or both,
based on the time since mixing satisfying a threshold.
54. The method of claim 53, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
55. The method of claim 47, further comprising: mixing two or more
components to form a second material associated with the second
extruder; and tracking a time since mixing, wherein the second
extruder is cleaned, purged, or both, based on the time since
mixing satisfying a threshold.
56. The method of claim 55, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
57. The method of claim 55, further comprising after depositing the
portion of the first material and before depositing a second
portion of the first material, cleaning the first extruder, purging
the first extruder, or cleaning and purging the first extruder.
58. The method of claim 47, further comprising depositing, using
the second extruder of the 3D printer device, a second material
after depositing the portion of the first material and before
depositing a second portion of the first material, wherein the
second material is chemically distinct from the first material.
59. The method of claim 47, wherein the first extruder comprises
filament-feed extruder and the second extruder comprises a paste
extruder.
60. The method of claim 47, wherein the second extruder comprises
filament-feed extruder and the first extruder comprises a paste
extruder.
61. A method comprising: obtaining model data representing a
three-dimensional (3D) model of an object; and processing the model
data to generate a set of commands to direct a 3D printer to
extrude a material to form a physical model associated with the
object, the set of commands executable to cause an extruder of the
3D printer to deposit a first portion of the material corresponding
to a first portion of the physical model, to clean, to purge, or to
clean and purge the extruder after depositing the first portion of
the material, and to deposit a second portion of the material after
cleaning the extruder, purging the extruder, or cleaning and
purging the extruder, the second portion of the material
corresponding to a second portion of the physical model.
62. The method of claim 61, further comprising storing data
representing the set of commands.
63. The method of claim 61, further comprising sending data
representing the set of commands to the 3D printer via a
communication interface.
64. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to track a quantity of the
material deposited to form the first portion of the physical model,
and to cause the 3D printer to clean, to purge, or to clean and
purge the extruder based on the quantity of the material deposited
satisfying a threshold.
65. The method of claim 61, wherein generating the set of commands
includes determining a quantity of the material to be deposited to
form the first portion of the physical model and including a
cleaning sequence in the set of commands based on the quantity of
the material deposited satisfying a threshold.
66. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to track a deposition time
associated with forming the first portion of the physical model and
to cause the 3D printer to clean, to purge, or to clean and purge
the extruder based on the deposition time satisfying a
threshold.
67. The method of claim 61, wherein generating the set of commands
includes determining a deposition time associated with forming the
first portion of the physical model and including a cleaning
sequence in the set of commands based on the deposition time
satisfying a threshold.
68. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to track downtime of a second
extruder and to clean, to purge, or to clean and purge the extruder
based on the downtime of the second extruder satisfying a
threshold.
69. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to mix two or more components to
form the material.
70. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to mix two or more components to
form the material, to track a time since mixing, and to clean, to
purge, or to clean and purge the extruder based on the time since
mixing satisfying a threshold.
71. The method of claim 70, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
72. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to mix two or more components to
form a second material associated with a second extruder of the 3D
printer, to track a time since mixing, and to clean, to purge, or
to clean and purge the extruder based on the time since mixing
satisfying a threshold.
73. The method of claim 72, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
74. The method of claim 72, wherein the set of commands is
executable to cause the 3D printer to clean, to purge, or to clean
and purge the second extruder after depositing the first portion of
the material and before depositing the second portion of the
material.
75. The method of claim 72, wherein the extruder comprises
filament-feed extruder and the second extruder comprises a paste
extruder.
76. The method of claim 61, wherein the set of commands is
executable to cause the 3D printer to deposit a second material
after depositing the first portion of the material and before
depositing the second portion of the material, wherein the second
material is chemically distinct from the material.
77. The method of claim 61, wherein the 3D model includes a first
model portion representing a matrix material and a second model
portion representing a filler material, and wherein processing the
model data includes: identifying a first region of the 3D model
that includes the matrix material and a second region of the 3D
model that includes the filler material, wherein at least a portion
of the second region is enveloped by at least a portion of the
first region in the 3D model; and automatically modifying the model
data to omit at least a portion of the matrix material from the
first region of the 3D model.
78. The method of claim 77, wherein dimensions of the portion of
the matrix material omitted from the first region of the 3D model
are determined based on physical dimensions of a second extruder
associated with the filler material.
79. The method of claim 61, wherein the set of commands includes
G-code commands.
80. A method comprising: obtaining model data representing a
three-dimensional (3D) model of an object; and processing the model
data to generate a set of commands to direct a 3D printer to
extrude one or more materials to form a physical model associated
with the object, the set of commands executable to cause a first
extruder of the 3D printer to deposit a portion of a first material
to form a first portion of the physical model and to, after
depositing the portion of the first material, clean a second
extruder of the 3D printer, purge the second extruder, or clean and
purge the second extruder.
81. The method of claim 80, further comprising storing data
representing the set of commands.
82. The method of claim 80, further comprising sending data
representing the set of commands to the 3D printer via a
communication interface.
83. The method of claim 80, wherein the set of commands is
executable to cause the 3D printer to track a quantity of the first
material deposited to form the first portion of the physical model,
and to cause the 3D printer to clean, to purge, or to clean and
purge the second extruder based on the quantity of the first
material deposited satisfying a threshold.
84. The method of claim 80, wherein generating the set of commands
includes determining a quantity of the first material to be
deposited to form the first portion of the physical model and
including a cleaning sequence to clean, to purge, or to clean and
purge the second extruder in the set of commands based on the
quantity of the first material deposited satisfying a
threshold.
85. The method of claim 80, wherein the set of commands is
executable to cause the 3D printer to track a deposition time
associated with forming the first portion of the physical model and
to cause the 3D printer to clean, to purge, or to clean and purge
the second extruder based on the deposition time satisfying a
threshold.
86. The method of claim 80, wherein generating the set of commands
includes determining a deposition time associated with forming the
first portion of the physical model and including a cleaning
sequence to clean, to purge, or to clean and purge the second
extruder in the set of commands based on the deposition time
satisfying a threshold.
87. The method of claim 80, wherein the set of commands is
executable to cause the 3D printer to track downtime of the second
extruder and to clean, to purge, or to clean and purge the second
extruder based on the downtime of the second extruder satisfying a
threshold.
88. The method of claim 80, wherein the set of commands is
executable to cause the 3D printer to mix two or more components to
form the first material.
89. The method of claim 80, wherein the set of commands is
executable to cause the 3D printer to mix two or more components to
form the first material, to track a time since mixing, and to
clean, to purge, or to clean and purge the second extruder based on
the time since mixing satisfying a threshold.
90. The method of claim 89, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
91. The method of claim 80, wherein the set of commands is
executable to cause the 3D printer to mix two or more components to
form a second material associated with the second extruder, to
track a time since mixing, and to clean, to purge, or to clean and
purge the second extruder based on the time since mixing satisfying
a threshold.
92. The method of claim 91, wherein the two or more components
include a resin and a hardening agent, wherein the two or more
components begin to cure upon mixing, and wherein the threshold is
based on cure time of a mixture including the two or more
components.
93. The method of claim 91, wherein the set of commands is
executable to cause the 3D printer to clean, to purge, or to clean
and purge the first extruder after depositing the portion of the
first material and before depositing a second portion of the first
material.
94. The method of claim 80, wherein the set of commands are further
executable to cause the 3D printer deposit a second material after
depositing the portion of the first material and before depositing
a second portion of the first material, wherein the second material
is chemically distinct from the first material.
95. The method of claim 80, wherein the 3D model includes a first
model portion representing a matrix material and a second model
portion representing a filler material, and wherein processing the
model data includes: identifying a first region of the 3D model
that includes the matrix material and a second region of the 3D
model that includes the filler material, wherein at least a portion
of the second region is enveloped by at least a portion of the
first region in the 3D model; and automatically modifying the model
data to omit at least a portion of the matrix material from the
first region of the 3D model.
96. The method of claim 95, wherein dimensions of the portion of
the matrix material omitted from the first region of the 3D model
are determined based on physical dimensions of an extruder
associated with the filler material, wherein the extruder
associated with the filler material corresponds to the first
extruder or corresponds to the second extruder.
97. The method of claim 80, wherein the first extruder comprises
filament-feed extruder and the second extruder comprises a paste
extruder.
98. The method of claim 80, wherein the set of commands includes
G-code commands.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/208,222, filed Aug. 21, 2015 and entitled
"Closed-Loop 3D Printing Incorporating Sensor Feedback," U.S.
Provisional Patent Application No. 62/340,389, filed May 23, 2016
and entitled "SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D)
PRINTER," U.S. Provisional Patent Application No. 62/340,421, filed
May 23, 2016 and entitled "SYSTEM AND METHOD TO CONTROL A
THREE-DIMENSIONAL (3D) PRINTER," U.S. Provisional Patent
Application No. 62/340,453, filed May 23, 2016 and entitled "SYSTEM
AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTING DEVICE,"
U.S. Provisional Patent Application No. 62/340,436, filed May 23,
2016 and entitled "SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL
(3D) PRINTER," and U.S. Provisional Patent Application No.
62/340,432, filed May 23, 2016 and entitled "3D PRINTER CALIBRATION
AND CONTROL;" the contents of each of the aforementioned
applications are expressly incorporated herein by reference in
their entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure is generally related to control of a
three-dimensional (3D) printer device.
BACKGROUND
[0003] Improvements in computing technologies and material
processing technologies have led to an increased interest in
computer-driven additive manufacturing techniques, such as
three-dimensional (3D) printing. Generally, 3D printing is
performed using a 3D printer device that includes an extruder, one
or more actuators, and a controller coupled to some form of
structural alignment system, such as a frame. The controller is
configured to control the extruder and the actuators to deposit
material, such as a polymer-based material, in a controlled
arrangement to form a physical object.
SUMMARY
[0004] In a particular implementation, a method includes obtaining
model data representing a three-dimensional (3D) model of an
object. The method also includes processing the model data to
generate a set of commands to direct a 3D printer to extrude a
material to form a physical model associated with the object. The
set of commands is executable to cause an extruder of the 3D
printer to deposit a first portion of the material corresponding to
a first portion of the physical model, to clean, to purge, or to
clean and purge the extruder after depositing the first portion of
the material, and to deposit a second portion of the material after
cleaning the extruder. The second portion of the material
corresponds to a second portion of the physical model.
[0005] In another particular implementation, a method includes
obtaining model data representing a three-dimensional (3D) model of
an object. The method also includes processing the model data to
generate a set of commands to direct a 3D printer to extrude one or
more materials to form a physical model associated with the object.
The set of commands is executable to cause a first extruder of the
3D printer to deposit a portion of a first material to form a first
portion of the physical model and to, after depositing the portion
of the first material, clean a second extruder of the 3D printer,
purge the second extruder, or clean and purge the second
extruder.
[0006] In a particular implementation, a three-dimensional (3D)
printer device includes a first extruder configured to deposit a
material on a deposition platform, an actuator coupled to at least
one of the first extruder or the deposition platform, and a
controller coupled to the actuator. The controller may be
configured to cause the first extruder to deposit a first portion
of the material corresponding to a first portion of a physical
model. The controller may be configured to cause the first extruder
to be cleaned, purged, or both, after the first extruder deposits
the first portion of the material. The controller may be configured
to cause the first extruder to deposit a second portion of the
material after the first extruder is cleaned. The second portion of
the material corresponds to a second portion of the physical
model.
[0007] In another particular implementation, a three-dimensional
(3D) printer device includes a first extruder configured to deposit
a first material on a deposition platform, a second extruder
configured to deposit a second material on the deposition platform,
an actuator coupled to the first extruder, the second extruder, the
deposition platform, or a combination thereof, and a controller
coupled to the actuator. The controller is configured to cause the
first extruder to deposit a first portion of the first material
corresponding to a first portion of a physical model and to cause
the second extruder to be cleaned, purged, or both, after the first
extruder deposits the first portion of the first material.
[0008] In another particular implementation, a method includes
depositing, using a first extruder of a three-dimensional (3D)
printer device, a first portion of a first material corresponding
to a first portion of a physical model of an object. The method
also includes cleaning, purging, or cleaning and purging the first
extruder after depositing the first portion of the first material.
The method further includes, after cleaning the first extruder,
depositing, using the first extruder, a second portion of the first
material, the second portion of the first material corresponding to
a second portion of the physical model.
[0009] In another particular implementation, a method includes
depositing, using a first extruder of a three-dimensional (3D)
printer device, a portion of a first material to form a first
portion of a physical model. The method further includes, after
depositing the portion of the first material, cleaning a second
extruder of the 3D printer device, purging the second extruder, or
cleaning and purging the second extruder.
[0010] The features, functions, and advantages that have been
described can be achieved independently in various implementations
or may be combined in yet other implementations, further details of
which are disclosed with reference to the following description and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram that illustrates a system that
includes a three-dimensional (3D) printing device, according to a
particular embodiment;
[0012] FIGS. 2A, 2B and 2C illustrate extruding a material by a 3D
printing device, according to particular embodiments;
[0013] FIGS. 3A, and 3B illustrate extruding a material by a 3D
printing device, according to particular embodiments;
[0014] FIG. 4 is a diagram that illustrates a particular embodiment
of a method of slicing a 3D model to form commands to control a 3D
printing device;
[0015] FIGS. 5, 6, 7, 8, 9, 10, 11, 12, 13, and 14 illustrate
various stages during printing of a physical model of the 3D model
of FIG. 4;
[0016] FIG. 15 is a flow chart of an example of a method that may
be performed by the system of FIG. 1;
[0017] FIG. 16 is a flow chart of an example of a method that may
be performed by the system of FIG. 1;
[0018] FIG. 17 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0019] FIG. 18 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0020] FIG. 19 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0021] FIG. 20 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0022] FIG. 21 is a flow chart of another example of a method that
may be performed by the system of FIG. 1; and
[0023] FIG. 22 is a flow chart of another example of a method that
may be performed by the system of FIG. 1.
DETAILED DESCRIPTION
[0024] A 3D printer may be a peripheral device that includes an
interface to a computing device. For example, the computing device
may be used to generate or access a 3D model of an object. In this
example, a computer-aided design (CAD) program may be used to
generate the 3D model. A slicer application may be to process the
3D model to generate commands that are executable by the 3D printer
to form a physical model of the object. For example, the slicer
application may generate G-code (or other machine instructions)
that instruct the controller of the 3D printer when and where to
move the extruder and provides information regarding 3D printer
settings, such as extruder temperature, material feed rate,
extruder movement direction, extruder movement speed, among
others.
[0025] The slicer application may generate the G-code or machine
instructions by dividing the 3D model into layers (also referred to
as "slices"). The slicer application determines a pattern of
material to be deposited to form a physical model of each slice.
Generally, the physical model of each slice is formed as a series
or set of lines of extruded material. The G-code (or other machine
instructions), when executed by the controller of the 3D printer,
cause the extruder to deposit a set of lines of the material in a
pattern to form each layer, and one layer is stacked upon another
to form the physical model. Layer stacking arrangements or support
members can also be used to form lines of the material that are
partially unsupported (e.g., arches).
[0026] There are many ways that the slicer application can arrange
the pattern of materials to be deposited to form each layer.
Characteristics of a 3D print job may vary depending on how the
slicer application arranges the pattern lines that make up each of
the layers. For example, two different patterns of lines may have
different printing characteristics, such as an amount of time used
to print the physical model, an amount of material used to print
the physical model, etc. As another example, two different patterns
of lines may result in physical models that have different
characteristics, such as interlayer adhesion, weight, durability,
etc. Accordingly, different slicer applications or different
settings or configurations of the slicer application can affect the
outcome of a particular 3D print job.
[0027] Besides the arrangement of the pattern of materials, other
factors can also affect print quality. For example, during
extrusion, some materials have a tendency to clog or partially clog
a nozzle of the extruder. As the nozzle begins to clog, the flow
properties of the nozzle change. To illustrate, a decreased flow
area of the nozzle can lead to forming lines that have decreased
cross-sectional area, which can reduce print quality. Additionally,
if a clog breaks loose during extrusion, the clog can be deposited
as a clump or other line deformity. As another example, some
materials may aggregate around the nozzle during extrusion to forms
clumps that do not occlude the nozzle but can nevertheless lead to
problems. These clumps of material can break loose during extrusion
to cause clumps or other line deformities in the deposited
material.
[0028] Accordingly, one method of improving print quality is to
periodically or occasionally interrupt the extrusion process to
clean the extruder, to purge the extruder, or both. The extruder
can be cleaned by moving the extruder to a cleaning station that
includes one or more brushes or scrapers. The brushes or scrapers
may be passive such that the extruder is moved across the brushes
or scrapers to remove excess material. Alternately, the brushes or
scrapers may be active (e.g., moving linearly or rotating) to
contact the extruder to remove excess material. The cleaning
station may also include a waste catcher to catch and retain the
removed excess material away from the object being printed. The
waste catcher may also be used to purge material from the extruder.
For example, material may be purged from the extruder when changing
from using a first material to using a second material. As another
example, if the material being deposited is reactive (e.g., cures
after being mixed or upon exposure to air) some or all of the
material may be purged when the extruder is cleaned to avoid curing
of the material in the extruder.
[0029] Different types of extruders may be used to deposit
different types of materials (e.g., physically or chemically
distinct materials). For example, a filament-fed extruder may be
used to deposit thermoplastic polymers, such as polylactic acid
(PLA), acrylonitrile butadiene styrene (ABS) polymers, and
polyamide, among others. Paste extruders, such as pneumatic or
syringe extruders, may be used to deposit materials that are
flowable at room temperature (or at a temperature controlled by the
3D printer). Examples of materials that may be deposited using
paste extruders include silicone polymers, polyurethane, epoxy
polymers. Paste extruders may be especially useful to deposit
materials that undergo curing upon exposure to air or when mixed
together (such as multi-component epoxies).
[0030] Some 3D printers include multiple extruders to improve print
speed or to enable printing with multiple different materials. For
example, a first extruder may be used to deposit a first material,
and a second extruder may be used to deposit second material. In
this example, the first and second materials may have different
visual, physical, electrical, chemical, mechanical, and/or other
properties. To illustrate, the first material may have a first
color, and the second material may have a second color. As another
illustrative example, the first material may have first chemical
characteristics (e.g., may be a thermoplastic polymer), and the
second material may have a second chemical characteristics (e.g.,
may be a thermoset polymer). As yet another illustrative example,
the first material may be substantially non-conductive, and the
second material may be conductive. In this example, the first
material may be used to form a structure or matrix, and the second
material may be used to form conductive lines or electrical
components (e.g., capacitors, resistors, inductors) of a
circuit.
[0031] When a 3D printer uses multiple extruders to deposit
multiple materials, one extruder may be idle (i.e., not extruding
material) while another is depositing material. For example, while
a first extruder is depositing a matrix material, a second extruder
may be idle. Idle extruders may be particularly subject to clogging
since flow of material through the extruder may reduce clogging. If
the idle extruder becomes clogged, it can lead to reduced print
quality as a result of clumps in material that is later deposited
by the extruder.
[0032] Accordingly, to improve print quality, a print job may be
periodically or occasionally interrupted to clean or purge an idle
extruder. To illustrate, after a first extruder deposits a first
portion of a first material to form part of a physical object, a
second extruder (that was idle while the first extruder deposited
the first portion of the first material) may be cleaned.
Subsequently, the print job may be resumed. For example, the first
extruder may deposit a second portion of the first material to form
another part of a physical object. Alternately, the second extruder
may deposit a second material, or a third extruder may deposit a
third material.
[0033] In some implementations, the first extruder may also be
cleaned while the print job is interrupted. For example, cleaning
of the first extruder and of the second extruder may be scheduled
so that both are cleaned when either one is to be cleaned.
[0034] In some implementations, cleaning operations may be encoded
in the G-code or other machine instructions. For example, the
slicer application may schedule cleaning operations for one
extruder or for multiple extruders. In this example, the G-code or
other machine instructions include a sequence of operations
associated with printing the physical model (e.g., extrusion
operations, extruder movement operations, etc.) and at least one
cleaning operation is embedded with the sequence of operations
associated with printing the physical model.
[0035] In other implementations, cleaning operations may be
scheduled or implemented by the controller of the 3D printer. For
example, the slicer application may provide G-code or other machine
instructions that specify a sequence of operations associated with
printing the physical model, and, during printing, the controller
may interrupt execution of the sequence of operations to perform
cleaning operations.
[0036] The cleaning operations may be performed based on an amount
of material deposited. For example, the slicer application may
determine a quantity of material that will be used to form a
portion of the physical model, and the slicer application may
insert a cleaning operation into the G-code or machine instructions
when the quantity of material that will be used to form the portion
satisfies a threshold. Alternately, the controller of the 3D
printer may track the quantity of material that has been deposited
and interrupt the printer to clean one or more extruders when the
quantity of material that has been deposited satisfies a threshold.
In other implementations, deposition time of an extruder, idle time
of an extruder, or both may be determined or tracked to schedule
cleaning operations.
[0037] Some materials begin curing (i.e., solidifying) upon
exposure to air or upon mixing. For example, two-part epoxies
include an epoxy resin and a hardening agent. After the epoxy resin
and the hardening agent are mixed, the mixture begins to cure. When
a 3D printer uses such materials, one or more extruders of the 3D
printer may be cleaned or purged based on a time since mixing the
materials (or a time since the materials were exposed to air). For
example, if a material that cures after mixing is to be used, the
slicer application may generate G-code (or other machine
instructions) for mixing the materials. In this example, the slicer
application may cause the materials to be mixed based on when the
mixture will be needed during printing of the physical model.
Additionally, the slicer application may track (e.g., by summing
deposition time of all extruders of the 3D printer) when to
schedule a cleaning operation or a purging operation to prevent the
mixture from curing in the extruder. In another example, the G-code
(or other machine instructions) include instructions for mixing the
materials, and the controller of the 3D printer determines (e.g.,
based on a timer) when to schedule a cleaning operation or a
purging operation to prevent the mixture from curing in the
extruder.
[0038] The arrangement of the pattern of materials to be deposited
to form each layer may be of particular concern for certain
materials. For example, certain materials have a tendency to form
blobs or other irregularly shaped deposits (sometimes referred to
as "kisses") at the start of a line, the end of a line, or both. A
kiss can cause an issue with layer stacking if a portion of the
kiss extends above the layer on which it is deposited. A kiss can
also, or in the alternative, cause an issue with line arrangement
with the layer being printed if the kiss extends beyond the width
of its line into an area associated with another line.
[0039] Slicing the 3D model in a manner that reduces line starts
and stops can reduce the number of kisses in a physical model. The
number of line starts and stops can be reduced by configuring the
slicer application to use as few lines as possible (or as few lines
as practical in view of other settings or goals) for each layer.
For example, when a line extends to an edge of the layer, rather
than ending the line, lifting the extruder head and moving to a new
location for the next line, the slicer application may instruct the
3D printer to turn the line (e.g., in a U-turn) to continue the
line in another direction.
[0040] The number of line starts and stops can also be reduced by
extending lines between layers. For example, when a first layer is
complete, rather than ending the line and lifting the extruder head
to begin printing the next layer, the line may be extended to
overlay a portion of the first layer to immediately begin printing
a portion of the second layer. To illustrate, if the first layer is
in a horizontal plane, the material forming the line may be
deposited to form a vertical or oblique riser up to a plane of the
second layer.
[0041] As another example, a first portion of a physical model may
be formed by stacking multiple layers of material (e.g., a base
layer and one or more additional layers at least partially
overlaying the base layer) before moving the extruder head to a
different location to form another portion of the base layer. In
this example, the multiple layers may be stacked using a single
continuous deposition step (e.g., with one start and one stop).
[0042] Another method that may be used to reduce kisses is to
perform additional steps at the end of a line. For example, when a
line ends, rather than ceasing extruder flow and lifting the
extruder head, the extruder head may be caused to move backward
(e.g., in a direction back along the line that was just deposited)
as the extruder flow is stopped, as the extruder head is lifted, or
both. Alternately, the extruder flow can be ceased before the line
end is reached. After the extruder reaches the line end, the
extruder head can be lifted and moved back along the line. By
causing the extruder head to backtrack along the line with flow
stopped or as flow stops, potential kiss at the line end can be
smoothed out.
[0043] Yet another method that may be used to reduce kisses is to
control extruder flow in a manner that accounts for acceleration of
the extruder head. For example, pressure applied to the material
being deposited, temperature of the material, filament feed rate,
or a combination thereof, may be used to control a flow rate of
material from the extruder. The G-code (or other machine
instructions) may include settings for the temperature, the
pressure, the filament feed rate, or a combination thereof.
Additionally, the G-code (or other machine instructions) may
include information indicating a velocity (e.g., speed and
direction of travel) for movement of the extruder head during
deposition. At the beginning of a line, the extruder head is not
able to instantaneously achieve the indicated velocity. Rather, due
to inertia and/or settings of the 3D printer, the extruder head
velocity gradually increases to the indicated velocity. During this
acceleration from a starting velocity to the indicated velocity, if
the same extruder flow rate is used as is used when the extruder is
at the indicated velocity, more material will be deposited at the
beginning of the line than in the remainder of the line. A similar
issue arises at the end of the line. That is, when the extruder
approaches the end of a line, the extruder is not able to
decelerate from the indicated velocity to an ending velocity (e.g.,
stopped) instantaneously. Rather, the extruder head velocity
gradually decreases to the ending velocity. During this
deceleration (i.e., negative acceleration), if the same extruder
flow rate is used as is used when the extruder is at the indicated
velocity, more material will be deposited at the end of the line
than in the remainder of the line. Accordingly, kisses or other
line irregularities can be reduced by controlling the flow rate of
the extruder based on an acceleration rate of the extruder.
[0044] FIG. 1 illustrates a particular embodiment of a system 100
that includes a 3D printer device 101 and a computing device 102.
The 3D printer device 101 and the computing device 102 may be
coupled via a communications bus 160, which may include a wired or
wireless communications interface. The 3D printer device 101 is
configured to generate physical models of objects based on a 3D
model or commands based on model data.
[0045] In a particular embodiment, the computing device 102
includes a processor 103 and a memory 104. The computing device 102
may include a 3D modeling application 106. The 3D modeling
application 106 may enable generation of 3D models, which can be
used to generate model data 107 descriptive of the 3D models. For
example, the 3D modeling application 106 may include a
computer-aided design application.
[0046] The computing device 102 or the 3D printer device 101
includes a slicer application 108. The slicer application 108 may
be configured to process the model data 107 to generate commands
109 that the 3D printer device 101 (or portions thereof) uses
during generation of a physical model of an object represented by
the model data 107. In the particular embodiment illustrated in
FIG. 1, the commands 109 may include G-code commands or other
machine instructions that are executable by the 3D printer device
101 (or a portion thereof). The computing device 102 may also
include a communications interface 105 that may be coupled via the
communication bus 160 to the 3D printer device 101. For example,
the 3D printer device 101 may be a peripheral device that is
coupled via a communication port to the computing device 102.
[0047] The 3D printer device 101 includes a frame 110 and support
members 111 arranged to support various components at the 3D
printer device 101. In particular embodiments, the 3D printer
device 101 may include a deposition platform 112. In other
embodiments, the 3D printer device 101 does not include a
deposition platform 112 and another substrate or surface may be
used for deposition. The 3D printer device 101 also includes one or
more printheads. For example, in the embodiment illustrated in FIG.
1, the 3D printer device 101 includes a first printhead 113, a
second printhead 114, and an Nth printhead 115. Although three
particular printheads are illustrated in FIG. 1, in other
embodiments, the 3D printer device 101 may include more than three
printheads or fewer than three printheads. Each printhead 113-115
includes a corresponding extruder with an extruder tip. For
example, the first printhead 113 includes a first extruder 130
having a first extruder tip 131, the second printhead 114 includes
a second extruder 132 having a second extruder tip 133, and the Nth
printhead 115 includes an Nth extruder 134 including an Nth
extruder tip 135.
[0048] Each printhead 113-115 is coupled to receive a material that
may be deposited to form a portion of a physical model of an
object. For example, the first printhead 113 may be coupled to a
first material container 119 that includes a first material 120. As
another example, the second printhead 114 may be coupled to a
second material container 121 that includes a second material 122.
The Nth printhead 115 may be coupled to a mixer 127. The mixer 127
may be coupled to a first component container 123 and a second
component container 125. The first component container 123 may be
configured to retain a first component 124, such as a resin. In
this example, the second container 125 may be configured to contain
a second component 126, such as a hardening agent. In the example
illustrated in FIG. 1, the first component container 123 and the
second component container 125 are coupled to the mixer 127 to
enable the mixer 127 to generate a mixture 128 that includes a
portion of the first component 124 and a portion of the second
component 126. The first component 124 and the second component 126
may be selected to begin hardening upon mixing. Thus, the mixture
128 may begin curing as soon as the mixer 127 has mixed the
components.
[0049] Proportions of the components 124, 126 supplied to the mixer
127 may be controlled by a controller 141 of the 3D printer device
101. The controller 141 may also, or in the alternative, control
one or more actuators 143 to move the deposition platform 112
relative to the printheads 113-115, to move the printheads 113-115
relative to the deposition platform 112, or both. For example, in a
particular configuration, the deposition platform 112 may be
configured to move in a Z direction 140. In this example, the
printheads 113-115 may be configured to move in an X direction 138
and a Y direction 139 relative to the deposition platform 112.
Thus, movement of one or more printheads 113-115 relative to the
deposition platform 112 may involve movement of the deposition
platform 112, movement of one or more of the printheads 113-115, or
movement of both the deposition platform 112 and the printheads
113-115. In other examples, the deposition platform 112 may be
stationary and one or more of the printheads 113-115 may be moved.
In yet other examples, the one or more printheads 113-115 may be
stationary and the deposition platform 112 may be moved.
[0050] The 3D printer device 101 of FIG. 1 also includes one or
more cleaning stations 136, one or more purging stations 137, or
both. The cleaning stations 136 may be configured to clean one or
more extruder tips, such as the first extruder tip 131, the second
extruder tip 133, the Nth extruder tip 135, or a combination
thereof. In the examples illustrated herein, each extruder tip 131,
133, 135 may be associated with a corresponding cleaning station,
as described further below. However, in other examples, one
cleaning station may be used for multiple extruder tips 131, 133,
135. The cleaning station 136 may include a scraper, brushes, or
other devices that are used to remove particulate or other foreign
matter from the extruder tips 131, 133, 135. In some examples, the
cleaning station 136 may be movable relative to the frame 110 or
printheads 113-115. For example, the cleaning station 136 may move
to the printheads 113-115 to clean the corresponding extruder tip
rather than the printheads 113-115 moving to the cleaning station
136.
[0051] The purging station 137 may be configured to receive a
material from one or more of the printheads 113-115 in order to
purge an extruder of the printhead 113-115. For example, the
mixture 128 may begin to cure upon mixing. Accordingly, the mixture
128, or a portion thereof, may be purged occasionally to avoid
curing of the mixture 128 within the extruder 134 or within the
mixer 127. As an example, when the Nth extruder 134 is purged, the
Nth printhead 115 may be moved adjacent to or over the purge
station 137, and at least a portion of the mixture 128 may be
extruded by the extruder 134 into the purge station 137. The purge
station 137 may be configured to be removable or replaceable such
that after the mixture 128 cures in the purge station 137, the
cured mixture 128 can be removed without damaging components of the
3D printer device 101. Other materials used by other extruders may
be deposited in the purge station 137 occasionally. For example,
the second material 122 may include a paste that begins to cure
upon exposure to air. In this example, the second extruder 132 may
be purged at the purge station 137 occasionally to avoid clogging
the second extruder tip 133, the second extruder 132, or both.
Further, the first material 120 may include a filament or other
thermoplastic polymer, and the first material 120 may be
occasionally purged at the purge station 137 in order to retain
desirable properties of the filament, to avoid clogging the
extruder 130, or both. When a printhead 113-115 is purged at the
purge station 137, the printhead 113-115 may also be cleaned at the
cleaning station 136 to prepare the printhead 113-115 for use.
[0052] The 3D printer device 101 may also include a memory 142
accessible to the controller 141. The controller 141 may include or
have access to one or more timers 144, one or more material
counters 145, or both. The material counters 145 may track a
quantity of materials in the material containers 119, 121, 123,
125, a quantity of material in the mixer 127, a quantity of each
material deposited to form a physical model of an object, etc. For
example, during formation of a first physical model (or a portion
of the first physical model), the first material 120 may be
deposited by the first printhead 113. During formation of the first
physical model, the material counter 145 may track a quantity of
the first material 120 that has been deposited. The material
counter 145 may also, or in the alternative, track a quantity of
material remaining. To illustrate, during formation of the first
physical model, while the first material 120 is being deposited,
the material counter 145 may track a quantity of the first material
120 that remains in the first material container 119. As another
example, when the mixture 128 is deposited to form a portion of the
physical model, the material counter 145 may track a quantity of
the mixture 128 remaining in the mixer 127. When the quantity of
material remaining in the mixer 127 is below a threshold, the
controller 141 may cause the mixture 128 to be purged at the purge
station 137 and may cause the first component container 123 and the
second component container 125 to provide the first component 124
and the second component 126, respectively, to the mixer 127 to
generate a new mixture 128. Alternatively, portions of the first
component 124 and the second component 126 may be added to an
existing mixture 128 in the mixer 127.
[0053] The timers 144 may track an amount of time associated with
particular activities of the 3D printer device 101. For example, a
first timer of the timers 144 may track a time since mixing the
mixture 128. The time since mixing the mixture 128 may be used to
determine when to purge the mixture 128. For example, the mixture
128 may be purged before a cure time associated with the mixture
128 is reached. The timers 144 may also, or in the alternatively,
track how long a particular printhead 113-115 has been idle. For
example, during deposition of the first material 120 to form a
portion of a physical model, the second material 122 may sit idle
in the second printhead 114 or in the second material container
121. Since the second material 122 may begin to cure upon exposure
to air, the portion of the second material 122 exposed at the
second extruder tip 133 may begin to cure, potentially causing a
clog. Accordingly, based on the timers 144 indicating that the
second printhead 114 has been sitting idle for a threshold amount
of time, a print activity being performed by the 3D printer device
101 may be interrupted to move the second printhead 114 to the
cleaning station 136, the purging station 137, or both, to remove a
portion of the second material 122 from the second extruder 132 to
avoid clogging the second extruder 132.
[0054] As another example, the timers 144 may indicate how long a
particular extruder has been in use. For example, when the first
extruder 130 is being used to deposit a portion of material
corresponding to a physical object, the first extruder 130 may be
cleaned periodically to remove excess material that occasionally
aggregates around the first extruder tip 131. Thus, based upon the
timers 144, a 3D printing operation being performed by the 3D
printer device 101 may be interrupted, and the first extruder 130
may be moved to the cleaning station 136, to the purging station
137, or both, to clean the first extruder tip 131.
[0055] After cleaning of a particular extruder has been performed,
the 3D printing operations may resume where they left off. For
example, when the first extruder 130 was being used to form a
portion of a physical model, and the timer 144 or the material
counter 145 indicated cleaning was needed, the print activity may
be interrupted, the first extruder 130 may be cleaned, purged or
both, and then the printing activity may resume with the first
extruder 130 depositing the first material to form a second portion
of the physical object. Alternatively, cleaning operations may be
scheduled based on the timers 144, the material counter 145, or
both, such that the cleaning and/or purging operations occurs
between uses of particular extruders. For example, while the first
extruder 130 is in use to form a first portion of a physical model,
the timers 144, the material counters 145, or both, may reach a
value indicating that cleaning is needed. After the first
operations being performed by the first extruder 130 is complete
(e.g., when an end point associated with the first extruder 130 is
reached), the cleaning operation may be performed. The cleaning
operation may include cleaning and/or purging the first extruder
130, the second extruder 132, the Nth extruder, or a combination
thereof. After the cleaning operation has been performed, printing
operations may resume, for example, with the second extruder
depositing the second material 122 to form a second portion of the
3D model of the physical object.
[0056] In a particular embodiment, the memory 142 includes cleaning
and purging control instructions 147. The cleaning and purging
control instructions 147 may include instructions (e.g., a cleaning
sequence of instructions, a purging sequence of instructions, or
both) that facilitate cleaning and purging of the printheads
113-115. For example, when the controller 141 determines that a
cleaning operation is to be performed, the controller 141 may
interrupt operations being performed at the 3D printer device 101
and execute the cleaning sequence of instructions of the cleaning
and purging control instructions 147. As another example, when the
controller 141 determines that a purging operation is to be
performed, the controller 141 may interrupt operations being
performed at the 3D printer device 101 and execute the purging
sequence of instructions of the cleaning and purging control
instructions 147.
[0057] In some implementations, the cleaning and purging control
instructions 147 may include thresholds associated with the timers
144, thresholds associated with the material counters 145, or both.
To illustrate, the thresholds may include a cure time associated
with the mixture 128 or a threshold time that precedes the cure
time at which the mixture 128 is to be purged and/or cleaned. As
another example, the thresholds may include a downtime limit
associated with one or more of the printheads 113-115. The downtime
limit may be used to determine whether one or more of the
printheads 113-115 should be cleaned based on a downtime of the
particular printhead. As another example, the thresholds may
include use time thresholds associated with the particular
printhead 113-115. The use time thresholds may indicate how long a
particular printhead 113-115 can be in use before cleaning and/or
purging of the particular printhead 113-115 is needed. As another
example, the thresholds may include material quantity thresholds
that indicate how much material a particular printhead 113-115 can
deposit before cleaning and/or purging of the particular printhead
113-115 is needed. In some implementations, the thresholds may be
stored as part of the settings 150.
[0058] The cleaning and purging control instructions 147 may also
include instructions that cause more than one printhead to be
cleaned at a time. For example, when the timers 144 or the material
counters 145 indicates that the first printhead 113 is to be
cleaned, the cleaning and control instructions 147 may also cause
the second printhead 114, the Nth printhead 115, or both, to be
cleaned, so that multiple cleaning operations are performed
concurrently or sequentially to reduce interruption to print
operations.
[0059] The memory 142 may also include calibration data 148. The
calibration data 148 may include information that indicates
relative positions of the printheads 113-115. In the particular
example illustrated in FIG. 1, the printheads 113-115 may be
independently movable by corresponding actuators 143 or may be
movable together by one or more actuators 143. The calibration data
148 may indicate distances between printheads 113-115, extruder
tips 131, 133, 135, or both. Additionally, or in the alternative,
the calibration data 148 may include information about ramp up
speeds associated with the actuators 143. For example, the ramp up
speeds may indicate how quickly a particular printhead 113-115 can
accelerate from stopped to a specified velocity. As another
example, the calibration data 148 may include extrusion rates or
deposition rates associated with one or more of the printheads
113-115 based on particular control parameters, such as temperature
of the extruder or extruder tip, pressure applied to the extruder
or extruder tip, a type of material being deposited, a material
feed rate, or a combination thereof. For example, the calibration
data 148 may include rheology data based on temperature associated
with the first material 120, the second material 122, or the
mixture 128. As another example, the calibration data 148 may
include rheology data associated with the mixture 128 over
time.
[0060] The memory 142 may also include test print data 151. The
test print data 151 may be used to generate at least a portion of
the calibration data 148. For example, the test print data 151 may
include commands to generate one or more test print objects using
multiple of the printheads 113-115. Positions, orientations, and
other information about the test print objects may be measured
after a test print is performed and the measurements may be used to
adjust the calibration data 148. For example, the 3D printer device
101 may include a measurement device, such as a scanning device
(not shown), that automatically measures the test print objects.
Alternately, the test print objects may be manually measured and
updated calibration data may be provided via a user interface (not
shown) or via the computing device 102.
[0061] The memory 142 may also include end-of-line-technique
instructions 149. The end-of-line-technique instructions 149
include instructions that enable formation of line ends having a
target width without undesired characteristics, such as bulges and
blobs. Examples of end-of-line techniques are described further
with reference to FIGS. 2A-2C and 3A-3B. The end-of-line-technique
instructions 149 may be applied to commands provided by an external
computing device, such as the computing device 102, in order to
improve line ends associated with physical models printed by the 3D
printer device 101. The end-of-line technique instructions 149 may
include instructions to implement the technique described with
reference to FIG. 2C, instructions to implement the technique
described with reference to FIG. 3B, other end-of-line techniques,
or a combination thereof.
[0062] Accordingly, the 3D printer device 101 enables use of
multiple printheads 113-115 with multiple distinct materials, such
as the first material 120, the second material 122, the mixture
128, or a combination thereof, to form physical models of 3D
objects corresponding to model data 107. The 3D printer device 101
is able to improve printing outcomes by controlling cleaning and
purging of the printheads 113-115 and by using improved end-of-line
techniques.
[0063] FIGS. 2A-2C illustrate use of end-of-line deposition
techniques. In FIG. 2A, an extruder 202 is illustrated depositing a
material 204 on a substrate, such as the deposition platform 112.
As the material 204 is extruded from the extruder 202, the tip of
the extruder 202 travels relative to the deposition platform 112 in
a direction 206.
[0064] In FIG. 2B, an end of a line being deposited is reached.
Using a conventional deposition technique, the extruder 202 ceases
extruding the material when the end of the line is reached. The
extruder 202 is subsequently moved in a direction 208 away from the
deposition platform 112. Because of residual pressure, a small
quantity of the material 204 may accumulate at the line end causing
a blob 210. Thus, use of the conventional deposition technique
illustrated in FIG. 2B may result in undesirable line
characteristics, such as the blob 210, which can lead to problems
with adhesion of subsequent layers and deformation of the physical
model.
[0065] FIG. 2C illustrates use of an improved end-of-line
deposition technique. In FIG. 2C, when an end of the line 214 is
reached, the tip of the extruder 202 is moved in a direction 212,
which is back along the line that was just deposited and away from
the deposition platform 112. An extrusion rate of the extruder 202
is reduced when the end of the line 214 is reach, before the end of
the line 214 is reached, or concurrently with movement of the tip
of the extruder 202 in the direction 212. As the tip of the
extruder 202 is moved backward along the line and away from the
deposition platform 112, any excess material extruded by the tip of
the extruder 202 may be spread more evenly along the end of the
line 214, resulting in a line with desirable end-of-line qualities.
In particular, the line does not terminate in a blob, such as the
blob 210. The improved end-of-line deposition technique illustrated
in FIG. 2C may be performed by a 3D printing device, such as the 3D
printer device 101 of FIG. 1, based on the end-of-line-technique
instructions 149. The tip of the extruder 202 illustrated in FIGS.
2A-2C may correspond to any of the extruder tips 131, 133, 135 of
the 3D printer device 101 of FIG. 1.
[0066] FIGS. 3A and 3B illustrate end-of-line techniques that may
be used by a 3D printing device, such as the 3D printer device 101
of FIG. 1. In a particular embodiment, the end-of-line technique
illustrated in FIG. 3B may be used by the 3D printer device 101 of
FIG. 1 based on the end-of-line techniques instructions 149.
[0067] FIG. 3A illustrates a conventional end-of-line technique. In
FIG. 3A, a graph 300 illustrates velocity of a printhead relative
to a deposition substrate, such as the deposition platform 112. The
graph 300 also indicates an extrusion rate of an extruder of the
printhead. The extrusion rate may include a mass flow rate or an
end-of-line flow rate. Alternatively, the extrusion rate may
correspond to a control parameter that is directly or inversely
related to the mass or volumetric flow rate, such as a pressure
applied to the extruder, a material feed rate, extruder
temperature, and so forth.
[0068] In the example illustrated in FIG. 3A, the graph 300 shows
that when the extruder begins to move, the extrusion rate is
adjusted to a desired extrusion rate value. Thus, the extrusion
rate jumps immediately or nearly immediately to the desired
extrusion rate while the extruder gradually accelerates to reach a
desired movement rate or velocity. Thus, in the graph 300, there is
initially a large gap between the extrusion rate and the velocity
of the extruder. The gap reduces as the extruder accelerates, and
eventually, the gap remains a relatively constant.
[0069] As a result of the initial gap, a larger quantity of
material is deposited at the beginning of the line 304 than at
other portions of the line 304, resulting in a blob 306 at the
beginning of the line 304. The blob 306 has a blob width 310 that
is significantly wider than a target line width 308 of the line
304. The blob 306 results from a difference between the amount of
time for the extruder to reach a desired velocity (e.g., an
acceleration rate of the extruder) and the amount of time for the
extrusion rate to reach a desired extrusion rate. For example, when
the extruder is a pasted extruder, pressure applied to a plunger of
the extruder results in virtually immediate extrusion at the
desired rate. In contrast, inertia and mechanical limitations limit
a rate at which the extruder can accelerate.
[0070] FIG. 3B illustrates an improved end-of-line technique in
which the extrusion rate is ramped as the velocity of the extruder
ramps. For example, as illustrated in a graph 320, the extrusion
rate (or a control parameter related to the extrusion rate) may be
gradually increased based on the acceleration rate of the extruder.
Accordingly, there is no large gap of the beginning of the line
between the velocity of the extruder and the extrusion rate.
[0071] A line 324 formed using the end-of-line technique
illustrated by the graph 320 is also illustrated in FIG. 3B. The
line 324 has a line end 326 having a width approximately the same
as the target line width 308. In order to perform the improved
end-of-line technique of FIG. 3B, the end-of-line-technique
instructions 149 may access the settings 150 to determine
information about the acceleration and extrusion rate of a
particular printhead. Additionally, although FIGS. 3A and 3B only
illustrate a beginning of a line, similar end-of-line techniques
may be performed at a termination point of a line. For example,
although FIG. 3B illustrates a relationship between the
acceleration rate of an extruder and an extrusion rate of the
extruder, a similar relationship occurs when the extruder slows
down when the end of a line being deposited is reached.
Accordingly, the extrusion rate of the extruder may be gradually
decreased as the extruder slows down to avoid forming a blob at the
end of the line.
[0072] FIG. 4 illustrates multiple steps associated with generating
commands 109, such as G-code instructions, based on a 3D model of
an object. In FIG. 4, a 3D model 400 is illustrated as an example
of various features disclosed herein. In operation, other 3D
models, including 3D models having different shapes, different
materials, etc. may be used. The 3D model 400 may include or be
based on model data 107 of FIG. 1. In FIG. 4, the 3D model 400 is
formed of multiple materials, including the first material 120 and
the second material 122. In the example illustrated in FIG. 4, the
first material 120 is used as a matrix material, and the second
material 122 is used as a filler material.
[0073] After obtaining the 3D model 400 or the model data 107, a
slicer application, such as the slicer application 108, may perform
slicing operations to generate the commands 109. In the example
illustrated in FIG. 4, preliminary slicing is performed to generate
a sliced model 402. The sliced model 402 includes multiple slices
404, 406, only two of which are illustrated. Each slice 404, 406
represents a single layer of a physical model based on the 3D
model. Each layer of the physical model includes one or more
materials. Accordingly, each slice 404, 406 may be divided into
regions, with each region corresponding to a particular material.
For example, the slice 404 includes a first region corresponding to
a portion of the first material 120 and a second region
corresponding to a portion of the second material 122. The slice
406 includes a first region corresponding to a portion of the first
material 120 and a second region in which no material is
present.
[0074] After the sliced model 402 is generated, the slicer
application 108 may modify one or more of the slices based on
characteristics of the 3D printer device to be used to print the
physical model of the 3D model 400. For example, the slicer
application 108 may access the settings 150, the calibration data
148, or both, associated with the 3D printer device 101 of FIG. 1.
Alternately, the settings 150, the calibration data 148, or both,
may be accessible at the memory 104 of the computing device 102 of
FIG. 1.
[0075] In the example illustrated in FIG. 4, the slice 414 is
modified relative to the slice 404 of the sliced model 402. For
example, in the slice 414, a larger second region associated with
the second material has been provided. The second region of the
slice 414 may be determined based on dimensions associated with an
extruder that deposits the second material. To illustrate, a size
of the second region of the slice 414 may be determined based on a
size of second extruder tip 133. For example, in order to improve
interlayer adhesion and/or printing characteristics, the slicer
application 108 may determine that, when the physical model is
printed, a portion of the second material 122 will be embedded
within the physical model (e.g., entirely enclosed by the first
material). Accordingly, the slicer application may determine that
an injection technique may be used to deposit at least the embedded
portion of the second material. The injection technique may inject
the second material into a tunnel formed by void regions in
multiple layers of the first material (rather than depositing
multiple layers of the second material, with one layer
corresponding to one slice of the sliced model 402).
[0076] For example, the slicer application may be configured to
generate commands that favor printing one material at a time, and
then print with a different material. To illustrate, a first
material may be used to form multiple layers corresponding to a set
of slices. Even when the slices include regions corresponding to a
second material, the slicer application may arrange the commands so
that all of the regions that use the first material are printed
first. Subsequently, regions that use the second material may be
printed, such as by printing on a non-planar surface formed by the
first material or by injecting the second material into tunnels or
voids defined in the first material. When the first material
encloses the second material, the first material may be deposited
until just before the access to a region that is ton include the
second material is closed off, then the second material may be
deposited, as illustrated in FIGS. 10-13.
[0077] As illustrated in FIG. 4, the slicer application may modify
some slices to enable using injection techniques. The modified
slices may improve printing using injection technique by, for
example, widening the area 412 to enable the second extruder tip
133 to fit within the opening correspondent to the area 412.
[0078] Modifying the slices results in a modified sliced model 410,
which may be further processed. For example, when a slice, such as
the slice 414, includes an enclosed void region 418, the slicer
application may process that slice 414 as multiple separate or
coupled polygons to limit or reduce starting and stopping a
deposition process. During formation of a physical model
corresponding to the 3D model 400, the void region 418 may
eventually be filled with the second material 122. However, during
deposition of the first material 120, the void region 418 remains
empty. The slicer application 108 may process the slice 414 to
generate multiple polygons, such as a first polygon 420, a second
polygon 422, a third polygon 424, and a fourth polygon 426. The
multiple polygons 420-426 may be generated and arranged such that
the void region 418 is surrounded by the polygons 420-426, each
polygon 420-426 is adjacent to the void region 418, and no polygon
420-426 includes an internal void region. Thus, each polygon
420-426 may be continuous (without spaces, openings, or holes), so
that each polygon 420-426 can be printed using continuous lines
thereby limiting starting and stopping a corresponding
printhead.
[0079] The second slice 406 may also be processed further. For
example, the second slice 406 includes multiple regions of the
first material 120 and a large gap region in which no material is
deposited. In this case, the slicer application 108 may identify
and separate the regions to generate separate stacks 430 and 432.
Each separate stack 430, 432 may be treated as a separate layer for
purposes of generating a tool path. For example, a tool path 434
may be generated for the first stack 430, and a tool path 436 may
be generated for the second stack 432. Although not illustrated in
FIG. 4, tool paths may also be generated for the polygons 420-426
and other slices of the modified sliced model 410. The tool paths
associated with all of the slices and materials together are
illustrated in FIG. 4 as a sliced and tool pathed model 440. The
sliced and tool pathed model 440 may be processed to generate the
commands 109.
[0080] In a particular embodiment, tool paths for multiple slices
of the sliced and tool pathed model 440 may be determined such that
a continuous line of material extends between multiple layers. For
example, as further described in FIG. 5, a tool path for multiple
layers of a single material may be generated such that a line of
material of a first layer extends a second layer, where the second
layer is stacked on the first layer.
[0081] Additionally, in some embodiments, one material may be
deposited on a nonplanar surface formed by another material. For
example, the slicer application may generate a tool path for
depositing the second material that extends across multiple layers
of the first material, as illustrated in FIG. 14.
[0082] Further, as described above and with reference to FIGS.
10-13, one material may be injection-molded within another
material. For example, the sliced and tool pathed model 440 is
arranged such that a portion of the second material 122 is injected
within cavities defined within the first material 120.
[0083] Thus, FIG. 4 illustrates operations that can be formed by a
slicer application, such as the slicer application 108, to improve
printer performance, to improve interlayer adhesion, to reduce
starting and stopping of printing with a particular printhead
(e.g., within a particular layer as well as in between layers). The
commands 109 or G-code may be provided to a 3D printing device,
such as the 3D printer device 101 of FIG. 1, to generate a physical
model of the 3D model 400.
[0084] FIGS. 5-14 illustrate particular aspects of forming a
physical object based on a 3D model. In the examples illustrated in
FIGS. 5-14, particular aspects of the 3D model 400 is used as
examples. For example, the commands 109 may be executed by the 3D
printer device of 101 of FIG. 1 to build a physical model of the 3D
model 400.
[0085] FIG. 5 illustrates an extruder 502 coupled to a support
member 111 and to a drive belt 510. The extruder 502 may include,
correspond to, or be included within one of the extruder 130, 132,
134 of FIG. 1. Although the examples illustrated in FIGS. 5-14
include a drive belt 510 coupled to an actuator (not shown), in
other examples, the extruder 502 may be coupled to other actuators
or devices to move the extruder 502 relative to the deposition
platform 112. Alternately, the deposition platform 112 may be moved
relative to the extruder 502.
[0086] In the example illustrated in FIG. 5, during a first stage
of formation of the physical model, the extruder 502 is moved in a
direction 506 to form a portion of a first stack 504. The portion
of the first stack 504 may correspond to the first stack 430 of
FIG. 4. FIGS. 5-14 are illustrated from a front view, however, as
illustrated more clearly by the tool path 434 of the first stack
430 of FIG. 4, the first stack 504 may include multiple lines or
rows of material per layer. In FIG. 5, the first stack 504 may be
arranged such that a line extends from a first layer onto a second
layer, where the second layer is stacked on the first layer. Thus,
in FIG. 5, a portion of the extruded material is stacked at 508.
Stacking the material, as illustrated at 508, may facilitate
interlayered adhesion between layers of the first stack 504.
[0087] FIG. 6 illustrates a second stage during formation of the
physical model. The second stage may be subsequent to the first
stage. In FIG. 6, the extruder 502 is moved in a U-turn or curve
512 in order to follow a tool path, such as the tool path 434
illustrated in FIG. 4, to complete the stack 504. The tool path may
enable using a single continuous line of extruded material to form
multiple rows of material in a layer.
[0088] FIG. 7 illustrates a third stage during formation of the
physical model. The third stage may be subsequent to the second
stage. In FIG. 7, the first stack 504 has been completed to a
height (i.e., second height 522) determined based on
characteristics of the 3D printer device being used. The second
height 522 may be selected by the slicer application described with
reference to FIG. 4, by the computing device 102, or by the
controller 141 of the 3D printer device 101. The second height 522
is less than a distance (e.g., first height 520) between the tip of
the extruder 502 and the support member 111 coupled to the extruder
502. For example, the second height 522 may be less than the first
height 520 by an amount that is less than a thickness of one layer
of the first stack (or by an amount that is less than two layers of
the first stack 504) to provide clearance for depositing another
stack (such as the second stack 514). Thus, the extruder 502 may be
able to deposit abase layer of the second stack 514 on the
deposition platform 112 without the first stack 504 coming in
contact with the support member 111.
[0089] FIG. 8 illustrates a fourth stage during formation of the
physical model. The fourth stage may be subsequent to the third
stage. In FIG. 8, additional components of the 3D printing device
are illustrated. For example, members 820 and 822 of a frame are
illustrated coupled to the support member 111. An extruder 802 is
also illustrated. For example, the extruder 502 may include or
correspond to the first printhead 113 (or the first extruder 130),
and the extruder 802 may include or correspond to the second
printhead 114 (or the second extruder 132) or to the Nth printhead
115 (or the Nth extruder 134).
[0090] In the example illustrated in FIG. 8, the extruder 502 is a
filament extruder configured to extrude a filament 810 that is feed
to the extruder 502 by drive members 812. A tip of the extruder 502
may be heated to melt the filament 810 for deposition. Further, in
the example illustrated in FIG. 8, the extruder 802 is a syringe
extruder that includes a plunger 804 coupled to a drive 806. The
drive 806 may include a pneumatic drive (e.g., a pressure regulator
and/or valve) or a mechanical drive. The drive 806 applies pressure
to the plunger 804 to cause a second material 808, to be extruded.
The second material may include a paste or a viscous liquid.
[0091] Additionally, the 3D printing device illustrated in FIG. 8
includes multiple cleaning stations, including a first cleaning
station 824 and a second cleaning station 826. The 3D printing
device in FIG. 8 also includes multiple purging stations, including
a first purging station 828 and a second purging station 830. In
the example illustrated in FIG. 8, the first stack 504 and the
second stack 514 have been printed as described with reference to
FIGS. 5-7. Additional layers 814 of the first material have also
been deposited, such that an opening 816 is provided in a top
portion of a partial physical model 801.
[0092] FIG. 9 illustrates a fifth stage during formation of the
physical model. The fifth stage may be subsequent to the fourth
stage. FIG. 9 illustrates cleaning the extruder 502. For example,
the extruder 502 may be moved to the first cleaning station 824 to
clean a tip of the extruder 502, e.g., to remove a clump 832 of the
filament 810 that is coupled to a tip of the extruder 502. During
cleaning, the first cleaning station 824 may be used to scrape the
extruder tip to remove the clump 832.
[0093] In FIG. 9, the extruder 502 may be cleaned based on a
determination that a deposition operation associated with the
extruder 502 is complete. That is, as many layers of the first
material as can be deposited without beginning to close of the
opening 816 have been formed. Alternatively, the extruder 502 may
be cleaned based on a time associated with forming the partial
physical model 801 or on a quantity of material deposited to form
the partial physical model 801.
[0094] FIG. 10 illustrates a sixth stage during formation of the
physical model. The sixth stage may be subsequent to the fifth
stage, prior to the fifth stage, or concurrent with the fifth
stage. In FIG. 10, the extruder 802 may be cleaned, purged, or
both. In the arrangement illustrated in FIGS. 8-14, the extruders
502 and 802 cannot be cleaned at the same time; however, in other
arrangements, cleansing stations may be arranged to allow cleaning
multiple extruders concurrently or simultaneously.
[0095] In a particular example, while the extruder 502 deposits the
material to form the partial physical model 801, the second
material 808 may sitting unused in the extruder 802. Accordingly,
as illustrated in FIG. 10, a portion 834 of the second material 808
may be purged into the second purge station 830 and a tip of the
extruder 802 may be cleaned using the second cleaning station 826
before deposition using the second material begins. In other
examples, the extruder 802 may be coupled to a mixer, such as the
mixer 127, the extruder 802 may be cleaned based on a cure time
associated with the mixture. In yet other examples, the extruder
802 may not need to be cleaned after formation of the partial
physical model 801 and the sixth stage illustrated in FIG. 10 may
be omitted.
[0096] FIG. 11 illustrates a seventh stage during formation of the
physical model. The seventh stage may be subsequent to the fifth
stage, subsequent to the sixth stage, or both. In FIG. 11, the
extruder 802 is used to deposit a portion of the second material
808 into the opening 816 defined in the first material. The second
material 808 may be injected into the opening 816. As illustrated
in FIG. 11, the opening 816 is sufficiently wide to accommodate a
tip of the extruder 802. In some examples, as illustrated and
discussed in FIG. 4, the opening 816 may be adjusted relative to an
original 3D model, such as the 3D model 400, in order to
accommodate the tip of the extruder 802, as described in the
modifying slices step of FIG. 4.
[0097] FIG. 12 illustrates an eighth stage during formation of the
physical model. The eighth stage may be subsequent to the seventh
stage. In FIG. 12, the second material 808 has been deposited in
the partial physical model 801 to form a partial physical model 803
that includes the partial physical model 801 formed of the first
material and filler 844 formed of the second material 808.
Additionally, the extruder 802 has been moved to the second
cleaning station 826 to be cleaned, purged, or both. For example,
after deposition of the filler 844, a clot 842 may be formed at the
tip of the extruder 802, which may be cleaned and removed at the
second cleaning station 826. As another example, the extruder 802
may be cleaned based on a quantity of the second material 808
deposited to form the filler 844 satisfying a threshold. As another
example, the extruder 802 may be cleaned based on a time to deposit
the second material 808 satisfying a threshold. As yet another
example, the extruder 802 may be cleaned based on a cure time
associated with the second material 808. Although not illustrated
in FIG. 12, the extruder 802 may also be purged during, before, or
after the eighth stage. Similarly, the extruder 502 may be cleaned,
purged, or both, during, before, or after the eighth stage.
[0098] FIG. 13 illustrates a ninth stage during formation of the
physical model. The ninth stage may be subsequent to the eighth
stage. In FIG. 13, after formation of the partial physical model
803, a portion 850 of the first material 810 may be deposited to
cover the filler 844 and to form a partial physical model 805
having non-planar surface 852.
[0099] FIG. 14 illustrates a tenth stage during formation of the
physical model. The tenth stage may be subsequent to the ninth
stage. In FIG. 14, a portion 854 of the second material 808 is
deposited on the non-planar surface 852. The extruder 802 may
follow a curvilinear tool path 856 to deposit the portion 854 on
the non-planar surface 852. Deposition of the portion 854 completes
formation of a physical model 807 corresponding to the 3D model 400
of FIG. 4.
[0100] FIG. 15 is a flowchart of a particular embodiment of a
method 1500 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1500 may be performed by the controller 141 of the 3D printer
device executing instructions from the memory 142. As another
example, the method 1500 may be performed by the processor 103 of
the computing device 102 executing instructions from the memory
104.
[0101] The method 1500 includes, at 1502, obtaining model data
representing a three-dimensional (3D) model of an object. For
example, the processor 103 of FIG. 1 may obtain the model data 107
by reading the model data 107 from the memory 104. As another
example, the controller 141 may obtain the model data 107 by
receiving the model data 107 via the communication interface
146.
[0102] The method 1500 includes, at 1504, processing the model data
to generate a set of commands to direct a 3D printer device to
extrude a material to form a physical model associated with the
object. The set of commands may be executable to cause an extruder
of the 3D printer device to deposit a first portion of the material
corresponding to a first portion of the physical model. The set of
commands may also be executable to cause the 3D printer device to
clean the extruder after depositing the first portion of the
material. The set of commands may further be executable to cause
the extruder of the 3D printer device to deposit a second portion
of the material after cleaning the extruder, where the second
portion of the material corresponds to a second portion of the
physical model.
[0103] For example, processing the model data may include
performing slicing operations, such as operations described with
reference to FIG. 4, for generate the commands 109. The set of
commands may include machine instruction, such as G-code commands.
The set of commands may be generated by the slicer application 108
of the computing device 102. Alternatively, if the 3D printer
device 101 includes a slicing application, the set of commands may
be generated by the controller 141 or another processor of the 3D
printer device 101.
[0104] In some implementations, the method 1500 may also include
storing data representing the set of commands, sending data
representing the set of commands to the 3D printer via a
communication interface, or both. For example, after the commands
109 of FIG. 1 are generated, the commands 109 may be stored at the
memory 104 of the computing device 102, sent to the 3D printer
device 101, or both.
[0105] In a first implementation, the set of commands is executable
to cause the 3D printer device 101 to track a quantity of the
material deposited to form the first portion of the physical model.
In a second implementation, a slicer application (such as the
slicer application 108) generating the set of commands may
determine a quantity of the material that will be deposited to form
the first portion of the physical model and may include a cleaning
sequence in the set of commands based on the quantity of the
material deposited satisfying a threshold. In either of these
implementations, the set of commands may be executable to cause the
3D printer device 101 to clean the extruder based on the quantity
of the material deposited satisfying a threshold. For example, in
the first implementation, when one of the material counters 145
indicates that the first extruder 130 has deposits a threshold
quantity of the first material 120, the first extruder 130 may be
cleaned (e.g., to avoid buildup of material around an opening of
the first extruder tip 131). In the second implementation, the set
of commands may be arranged sequentially, and the first extruder
130 may be cleaned when the cleaning sequence is reached.
[0106] Alternately, the first implementation, the second
implementation, or both, may be based on deposition time rather
than quantity of material deposited. To illustrate, in the first
implementation, the set of commands is executable to cause the 3D
printer device 101 to track a deposition time associated with
forming the first portion of the physical model. In a second
implementation, a slicer application (such as the slicer
application 108) generating the set of commands may determining a
deposition time associated with forming the first portion of the
physical model and may include a cleaning sequence in the set of
commands based on the deposition time satisfying a threshold. In
either of these implementations, the set of commands may be
executable to cause the 3D printer device 101 to clean the extruder
based on the deposition time satisfying a threshold. For example,
in the first implementation, when one of the timers 144 indicates
that the first extruder 130 has been depositing the first material
for a threshold amount of time, the first extruder 130 may be
cleaned.
[0107] In yet another implementation, the set of commands is
executable, while a particular extruder (e.g., the first extruder
130) is in use, to cause the 3D printer device to track downtime of
another extruder (e.g., the second extruder 132 of the Nth extruder
134 or FIG. 1) that is not in use and to clean the particular
extruder (e.g., the first extruder 130) based on the downtime of
the other extruder (e.g., the second extruder 132 of the Nth
extruder 134) satisfying a threshold.
[0108] In some implementations, the set of commands is executable
to cause the 3D printer to mix two or more components to form the
material. For example, the set of commands may be executable by the
3D printer device 101 to provide the first component 124 (e.g., a
resin) and the second component 126 (e.g., a hardening agent) to
the mixer 127 to form the mixture 128. In such implementations, the
set of commands may cause the 3D printer device to clean the
extruder based on the time since mixing satisfying a threshold. For
example, the two or more components may begin to cure upon mixing,
and the threshold may be based on a cure time of the mixture. In
such implementations, the material extruded to form the first
portion of the physical model may include or correspond to the
mixture.
[0109] Alternatively, in a particular embodiment, the mixture may
be used by a second extruder. In this embodiment, the set of
commands may be executable to cause the 3D printer device to clean
the second extruder after depositing the first portion of the
material and before depositing the second portion of the
material.
[0110] In some implementations, the set of commands is executable
to cause the 3D printer device to deposit a second material after
depositing the first portion of the material and before depositing
the second portion of the material. The second material may be
chemically distinct from the material. For example, the 3D model
may include a first model portion representing a matrix material
(e.g., a first material) and a second model portion representing a
filler material (e.g., a second material). In this example,
processing the model data may include identifying a first region of
the 3D model that includes the matrix material and a second region
of the 3D model that includes the filler material. For some 3D
models, at least a portion of the second region may be enveloped by
at least a portion of the first region in the 3D model. In this
example, the processing the model data may also include
automatically modifying the model data to omit at least a portion
of the matrix material from the first region of the 3D model. For
example, a portion of the matrix material may be omitted to enable
a second extruder tip to enter an opening in the matrix material to
deposit the filler material. In this example, dimensions of the
portion of the matrix material omitted from the first region of the
3D model may be determined based on physical dimensions of the
second extruder.
[0111] FIG. 16 is a flowchart of a particular embodiment of a
method 1600 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1600 may be performed by the controller 141 of the 3D printer
device executing instructions from the memory 142. As another
example, the method 1600 may be performed by the processor 103 of
the computing device 102 executing instructions from the memory
104.
[0112] The method 1600 includes, at 1602, obtaining model data
representing a three-dimensional (3D) model of an object. For
example, the processor 103 of FIG. 1 may obtain the model data 107
by reading the model data 107 from the memory 104. As another
example, the controller 141 may obtain the model data 107 by
receiving the model data 107 via the communication interface
146.
[0113] The method 1600 includes, at 1604, processing the model data
to generate a set of commands to direct a 3D printer device to
extrude one or more materials to form a physical model associated
with the object. The set of commands may be executable to cause a
first extruder of the 3D printer device to deposit a first portion
of a first material corresponding to a first portion of the
physical model. The set of commands may also be executable to cause
the 3D printer device to clean a second extruder of the 3D printer
after depositing the portion of the first material.
[0114] For example, processing the model data may include
performing slicing operations, such as operations described with
reference to FIG. 4, for generate the commands 109. The set of
commands may include machine instruction, such as G-code commands.
The set of commands may be generated by the slicer application 108
of the computing device 102. Alternatively, if the 3D printer
device 101 includes a slicing application, the set of commands may
be generated by the controller 141 or another processor of the 3D
printer device 101.
[0115] In some implementations, the method 1600 may also include
storing data representing the set of commands, sending data
representing the set of commands to the 3D printer via a
communication interface, or both. For example, after the commands
109 of FIG. 1 are generated, the commands 109 may be stored at the
memory 104 of the computing device 102, sent to the 3D printer
device 101, or both.
[0116] In a first implementation, the set of commands is executable
to cause the 3D printer device 101 to track a quantity of the first
material deposited to form the first portion of the physical model.
In a second implementation, a slicer application (such as the
slicer application 108) generating the set of commands may
determine a quantity of the first material that will be deposited
to form the first portion of the physical model and may include a
cleaning sequence in the set of commands based on the quantity of
the first material deposited satisfying a threshold. In either of
these implementations, the set of commands may be executable to
cause the 3D printer device 101 to clean the second extruder based
on the quantity of the material deposited satisfying a threshold.
For example, in the first implementation, when one of the material
counters 145 indicates that the first extruder 130 has deposits a
threshold quantity of the first material 120, the second extruder
132 may be cleaned. In the second implementation, the set of
commands may be arranged sequentially, and the second extruder 132
may be cleaned when the cleaning sequence is reached.
[0117] Alternately, the first implementation, the second
implementation, or both, may be based on deposition time rather
than quantity of material deposited. To illustrate, in the first
implementation, the set of commands is executable to cause the 3D
printer device 101 to track a deposition time associated with
forming the first portion of the physical model. In a second
implementation, a slicer application (such as the slicer
application 108) generating the set of commands may determining a
deposition time associated with forming the first portion of the
physical model and may include a cleaning sequence in the set of
commands based on the deposition time satisfying a threshold. In
either of these implementations, the set of commands may be
executable to cause the 3D printer device 101 to clean the second
extruder based on the deposition time of the first extruder
satisfying a threshold. For example, in the first implementation,
when one of the timers 144 indicates that the first extruder 130
has been depositing the first material for a threshold amount of
time, the second extruder 132 may be cleaned.
[0118] In yet another implementation, the set of commands is
executable, while the first extruder 130 is in use, to cause the 3D
printer device 101 to track downtime of the second extruder 132,
which is not in use and to clean the second extruder 132 based on
the downtime of the second extruder 132 satisfying a threshold.
[0119] In some implementations, the set of commands is executable
to cause the 3D printer device to mix two or more components to
form the first material or to form a second material used by the
second extruder. For example, the set of commands may be executable
by the 3D printer device 101 to provide the first component 124
(e.g., a resin) and the second component 126 (e.g., a hardening
agent) to the mixer 127 to form the mixture 128. In such
implementations, the set of commands may cause the 3D printer
device to clean the second extruder based on the time since mixing
satisfying a threshold. In an embodiment, the two or more
components may begin to cure upon mixing, and the threshold may be
based on a cure time of the mixture. The mixture may be used by a
second extruder. In this embodiment, the set of commands may be
executable to cause the 3D printer device to clean the second
extruder after depositing the first portion of the first material
and before depositing a second portion of the first material.
[0120] In some implementations, the set of commands is executable
to cause the 3D printer device to deposit a second material after
depositing the first portion of the first material and before
depositing a second portion of the first material. The second
material may be chemically distinct from the first material. For
example, the 3D model may include a first model portion
representing a matrix material (e.g., a first material) and a
second model portion representing a filler material (e.g., a second
material). In this example, processing the model data may include
identifying a first region of the 3D model that includes the matrix
material and a second region of the 3D model that includes the
filler material. For some 3D models, at least a portion of the
second region may be enveloped by at least a portion of the first
region in the 3D model. In this example, the processing the model
data may also include automatically modifying the model data to
omit at least a portion of the matrix material from the first
region of the 3D model. For example, a portion of the matrix
material may be omitted to enable a second extruder tip to enter an
opening in the matrix material to deposit the filler material. In
this example, dimensions of the portion of the matrix material
omitted from the first region of the 3D model may be determined
based on physical dimensions of the second extruder.
[0121] FIG. 17 is a flowchart of a particular embodiment of a
method 1700 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1700 may be performed by the 3D printer device 101 executing
instructions from the memory 142.
[0122] The method 1700 includes, at 1702, depositing, using a first
extruder of a three-dimensional (3D) printer device, a first
portion of a first material corresponding to a first portion of a
physical model of an object. For example, the 3D printer device 101
of FIG. 1 may use the first extruder 130 to deposit the first
material 120 to form a first portion of a physical model of an
object (such as the partial physical model 801 of FIG. 8).
[0123] The method 1700 includes, at 1704, cleaning the first
extruder after depositing the first portion of the first material.
For example, the first extruder 130 may be cleaned at the cleaning
station 136 after the first extruder deposits the first material
120 to form a first portion of a physical model of an object. As
another example, after the partial physical model 801 is formed as
illustrated in FIG. 8, the extruder 502 may be cleaned as
illustrated in FIG. 9.
[0124] The method 1700 also includes, at 1706, after cleaning the
first extruder, depositing, using the first extruder, a second
portion of the first material, the second portion of the first
material corresponding to a second portion of the physical model.
For example, the first extruder 130 may be may be used to deposit
the first material 120 to form a second portion of a physical model
of an object after the first extruder 130 is cleaned. As another
example, after the first extruder is cleaned, as illustrated in
FIG. 9, the first extruder may be used to deposit a second portion
of the physical model, as illustrated in FIG. 13.
[0125] In some implementations, the method 1700 may also include
storing, at a memory of the 3D printer device, data representing a
set of commands to form the physical model, sending data
representing the set of commands via a communication interface, or
both. For example, after the commands 109 of FIG. 1 are generated,
the commands 109 may be stored at the memory 104 of the computing
device 102, sent to the 3D printer device 101, or both.
[0126] In a particular embodiment, the method 1700 includes
tracking a quantity of the first material deposited to form the
first portion of the physical model. In this embodiment, the first
extruder may be cleaned based on the quantity of the first material
deposited satisfying a threshold.
[0127] In a particular embodiment, the method 1700 includes
tracking a deposition time associated with forming the first
portion of the physical model. In this embodiment, the first
extruder may be cleaned based on the deposition time satisfying a
threshold.
[0128] In a particular embodiment, the method 1700 includes
tracking downtime of a second extruder of the 3D printer device. In
this embodiment, the first extruder may be cleaned based on the
downtime of the second extruder satisfying a threshold.
[0129] In a particular embodiment, the method 1700 includes mixing
two or more components to form the first material and tracking a
time since mixing. In this embodiment, the first extruder may be
cleaned based on the time since mixing satisfying a threshold. For
example, the two or more components may include a resin and a
hardening agent that begin to cure upon mixing. In this example,
the threshold may be based on a cure time of a mixture including
the two or more components. Mixing the two or more components may
include dispensing a resin from a first container of the 3D printer
device into a mixer of the 3D printer device and dispensing a
hardening agent from a second container of the 3D printer device
into the mixer. The resin and the hardening agent may be mixed in
the mixer, and the mixer may be in fluid communication with the
first extruder.
[0130] In a particular embodiment, the method 1700 includes mix two
or more components to form a second material associated with a
second extruder of the 3D printer device and tracking a time since
mixing. In this embodiment, the first extruder may be cleaned based
on the time since mixing satisfying a threshold. For example, the
two or more components may include a resin and a hardening agent
that begin to cure upon mixing, and the threshold may be based on a
cure time of a mixture. In this example, the method 1700 may
include cleaning the second extruder after depositing the first
portion of the first material and before depositing the second
portion of the first material.
[0131] The method 1700 may also or in the alternative include,
after depositing the first portion of the first material and before
depositing the second portion of the first material depositing a
second material using a second extruder of the 3D printer device.
The second material may be chemically distinct from the first
material.
[0132] FIG. 18 is a flowchart of a particular embodiment of a
method 1800 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1800 may be performed by the 3D printer device 101 executing
instructions from the memory 142.
[0133] The method 1800 includes, at 1802, depositing, using a first
extruder of a three-dimensional (3D) printer device, a portion of a
first material to form a first portion of a physical model. For
example, the 3D printer device 101 of FIG. 1 may use the first
extruder 130 to deposit the first material 120 to form a first
portion of a physical model of an object (such as the partial
physical model 801 of FIG. 8).
[0134] The method 1800 includes, at 1804, after depositing the
portion of the first material, cleaning a second extruder of the 3D
printer device. For example, after the first extruder 130 is used
to deposit the first material 120 to form the first portion of a
physical model, the second extruder 132 may be cleaned. As another
example, after the extruder 502 is used to form a first portion of
a physical model of an object (such as the partial physical model
801 FIG. 8), the extruder 802 may be cleaned, as illustrated in
FIG. 10.
[0135] In some implementations, the method 1800 may also include
storing, at a memory of the 3D printer device, data representing a
set of commands to form the physical model, sending data
representing the set of commands via a communication interface, or
both. For example, after the commands 109 of FIG. 1 are generated,
the commands 109 may be stored at the memory 104 of the computing
device 102, sent to the 3D printer device 101, or both.
[0136] In a particular embodiment, the method 1800 includes
tracking a quantity of the first material deposited to form the
first portion of the physical model. In this embodiment, the second
extruder may be cleaned based on the quantity of the first material
deposited satisfying a threshold.
[0137] In a particular embodiment, the method 1800 includes
tracking a deposition time associated with forming the first
portion of the physical model. In this embodiment, the second
extruder may be cleaned based on the deposition time satisfying a
threshold.
[0138] In a particular embodiment, the method 1800 includes
tracking downtime of the second extruder of the 3D printer device.
In this embodiment, the second extruder may be cleaned based on the
downtime of the second extruder satisfying a threshold.
[0139] In a particular embodiment, the method 1800 includes mixing
two or more components to form the first material and tracking a
time since mixing. In this embodiment, the first extruder may be
cleaned based on the time since mixing satisfying a threshold. For
example, the two or more components may include a resin and a
hardening agent that begin to cure upon mixing. In this example,
the threshold may be based on a cure time of a mixture including
the two or more components. Mixing the two or more components may
include dispensing a resin from a first container of the 3D printer
device into a mixer of the 3D printer device and dispensing a
hardening agent from a second container of the 3D printer device
into the mixer. The resin and the hardening agent may be mixed in
the mixer, and the mixer may be in fluid communication with the
first extruder.
[0140] In a particular embodiment, the method 1800 includes mix two
or more components to form the first material and tracking a time
since mixing. In this embodiment, the second extruder may be
cleaned based on the time since mixing satisfying a threshold. For
example, the two or more components may include a resin and a
hardening agent that begin to cure upon mixing, and the threshold
may be based on a cure time of the mixture. In this example, the
method 1800 may include cleaning the second extruder after
depositing the first portion of the first material.
[0141] In a particular embodiment, the method 1800 includes mix two
or more components to form a second material associated with the
second extruder and tracking a time since mixing. In this
embodiment, the second extruder may be cleaned based on the time
since mixing satisfying a threshold. For example, the two or more
components may include a resin and a hardening agent that begin to
cure upon mixing, and the threshold may be based on a cure time of
the mixture. In this example, the method 1800 may include cleaning
the second extruder after depositing the first portion of the first
material.
[0142] The method 1800 may also or in the alternative include,
after depositing the first portion of the first material and before
depositing a second portion of the first material depositing a
second material using a second extruder of the 3D printer device.
The second material may be chemically distinct from the first
material.
[0143] FIG. 19 is a flowchart of a particular embodiment of a
method 1900 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1900 may be performed by the 3D printer device 101 executing
instructions from the memory 142.
[0144] The method 1900 includes, at 1902, moving an extruder of a
3D printer device relative to a deposition platform of the 3D
printer device during deposition a material (e.g., a polymer) to
form a portion of a first line. For example, one or more of the
extruders 130, 132, 134 of FIG. 1 may be moved in the X direction
138, in the Y direction 139, or both, relative to the deposition
platform 112. As another example, the extruder 202 of FIG. 2A may
be moved in the direction 206 relative to the deposition platform
112 while the material 204 is deposited to form a portion of a
line.
[0145] The method 1900 includes, at 1904, after depositing a
portion of the material corresponding to a first end of the first
line, moving the extruder back along the first line and
concurrently moving the extruder away from the deposition platform.
For example, after depositing end of a line, one or more of the
extruders 130, 132, 134 of FIG. 1 may be moved in the X direction
138, in the Y direction 139, or both, relative to the deposition
platform 112 and concurrently moved in the Z direction 140 away
from the deposition platform. As another example, the extruder 202
of FIG. 2C may be moved in the direction 212 which is back along
the line formed by the material 204 and away from the deposition
platform 112. In this context, motion of the extruder relative to
the deposition platform 112 may be accomplished by moving the
extruder, moving the deposition platform, or both. To illustrate,
in FIG. 2C, the extruder 202 may be moved in a direction opposite
the direction 206 of FIG. 2A and the deposition platform 112 may be
lowered to move away from the extruder 202. Alternatively, one of
the extruder 202 or the deposition platform 112 may be stationary
while the other is moved.
[0146] The method 1900 may also include reducing an extrusion flow
rate of the extruder as the extruder moves away from the deposition
platform. For example, when the extruder is a paste extruder or
syringe type extruder, pressure applied to a plunger of the
extruder may be reduced as the extruder moves away from the
deposition platform. As another example, when the extruder is a
filament-fed extruder, a feed rate of the filament may be reduced
as the extruder moves away from the deposition platform.
[0147] In a particular embodiment, the method 1900 may include
forming a physical model by depositing multiple lines of the
material including the first line. For example, depositing the
multiple lines may include forming a base layer of the material on
the deposition platform and stacking multiple layers of the
material on the base layer. As another example, depositing the
multiple lines may include forming a first stack of multiple layers
of the material at a first location relative to the deposition
platform and after forming the first stack, forming a second stack
of multiple layers of the material at a second location relative to
the deposition platform. In this example, the first stack may be
formed to a height determined based on a physical configuration of
the 3D printer device before the second stack is formed. The
physical configuration of the 3D printer device may include or
correspond to a distance between an extruder tip of the extruder
and a support member coupled to the extruder. To illustrate, in
FIGS. 5-7, the first stack 504 is formed by depositing a plurality
of lines (arranged as layers) on the deposition platform. After the
first stack 504 reaches the second height 522 (which is less that
the first height 520), the second stack 514 is formed. In some
embodiments, the first line forms at least a portion of a first
layer and at least a portion of a second layer, wherein the second
layer is stacked on the first layer, as illustrated in FIG. 5.
[0148] In a particular embodiment, the method 1900 may include
depositing multiple layers of the material including the first line
to form a first portion of a physical model defining a non-planar
surface and using a second extruder of the 3D printer device to
deposit at least one additional material on the non-planar surface
to form a second portion of the physical model. For example, after
the extruder 502 is used to deposit a first material to form the
non-planer surface 852 of FIG. 14, the extruder 802 may be used to
deposit a portion of the second material 808 on the non-planar
surface 852.
[0149] FIG. 20 is a flowchart of a particular embodiment of a
method 2000 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
2000 may be performed by the 3D printer device 101 executing
instructions from the memory 142.
[0150] The method 2000 includes, at 2002, during extrusion of a
material (e.g., a polymer) by an extruder of a three-dimensional
(3D) printer device, moving the extruder relative to a deposition
platform of the 3D printer device. For example, one or more of the
extruders 130, 132, 134 of FIG. 1 may be moved in the X direction
138, in the Y direction 139, or both, relative to the deposition
platform 112. As another example, the extruder 202 of FIG. 2A may
be moved in the direction 206 relative to the deposition platform
112 while the material 204 is deposited to form a portion of a
line.
[0151] The method 2000 includes, at 2004, during movement of the
extruder, adjusting an extrusion rate of the extruder based on an
acceleration rate of relative motion of the extruder and the
deposition platform. For example, as described with reference to
FIG. 3B, the extrusion rate (or an extrusion rate control
parameter) may be adjusted based on an acceleration rate of the
relative motion of the extruder and the deposition platform to
enable formation of line ends (such as the line end 326) without
deformations or irregularities, such as blobs.
[0152] In a particular embodiment, the method 2000 may include
forming a physical model by depositing multiple lines of the
material including the first line. For example, depositing the
multiple lines may include forming a base layer of the material on
the deposition platform and stacking multiple layers of the
material on the base layer. As another example, depositing the
multiple lines may include forming a first stack of multiple layers
of the material at a first location relative to the deposition
platform and after forming the first stack, forming a second stack
of multiple layers of the material at a second location relative to
the deposition platform. In this example, the first stack may be
formed to a height determined based on a physical configuration of
the 3D printer device before the second stack is formed. The
physical configuration of the 3D printer device may include or
correspond to a distance between an extruder tip of the extruder
and a support member coupled to the extruder. To illustrate, in
FIGS. 5-7, the first stack 504 is formed by depositing a plurality
of lines (arranged as layers) on the deposition platform. After the
first stack 504 reaches the second height 522 (which is less that
the first height 520), the second stack 514 is formed. In some
embodiments, the first line forms at least a portion of a first
layer and at least a portion of a second layer, wherein the second
layer is stacked on the first layer, as illustrated in FIG. 5.
[0153] In a particular embodiment, the method 2000 may include
depositing multiple layers of the material including the first line
to form a first portion of a physical model defining a non-planar
surface and using a second extruder of the 3D printer device to
deposit at least one additional material on the non-planar surface
to form a second portion of the physical model. For example, after
the extruder 502 is used to deposit a first material to form the
non-planer surface 852 of FIG. 14, the extruder 802 may be used to
deposit a portion of the second material 808 on the non-planar
surface 852.
[0154] FIG. 21 is a flowchart of a particular embodiment of a
method 2100 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
2100 may be performed by the controller 141 of the 3D printer
device executing instructions from the memory 142. As another
example, the method 2100 may be performed by the processor 103 of
the computing device 102 executing instructions from the memory
104.
[0155] The method 2100 includes, at 2102, obtaining model data
representing a three-dimensional (3D) model of an object. For
example, the processor 103 of FIG. 1 may obtain the model data 107
by reading the model data 107 from the memory 104. As another
example, the controller 141 may obtain the model data 107 by
receiving the model data 107 via the communication interface
146.
[0156] The method 2100 includes, at 2104, processing the model data
to generate a set of commands to direct a 3D printer device to
extrude a material (e.g., a polymer) to form a physical model
associated with the object. The set of commands includes one or
more first commands to cause relative motion of an extruder of the
3D printer device and a deposition platform of the 3D printer
device during deposition a first portion of the material to form a
portion of a first line. The one or more first commands are further
executable to, after depositing a second portion of the material
corresponding to a first end of the first line, cause relative
motion of the extruder and the deposition platform such that the
extruder moves back along the first line while the extruder
concurrently moves away from the deposition platform. For example,
after depositing an end of a line, one or more of the extruders
130, 132, 134 of FIG. 1 may be moved in the X direction 138, in the
Y direction 139, or both, relative to the deposition platform 112
and concurrently moved in the Z direction 140 away from the
deposition platform. As another example, the extruder 202 of FIG.
2C may be moved in the direction 212 which is back along the line
formed by the material 204 and away from the deposition platform
112. In this context, motion of the extruder relative to the
deposition platform 112 may be accomplished by moving the extruder,
moving the deposition platform, or both. To illustrate, in FIG. 2C,
the extruder 202 may be moved in a direction opposite the direction
206 of FIG. 2A and the deposition platform 112 may be lowered to
move away from the extruder 202. Alternatively, one of the extruder
202 or the deposition platform 112 may be stationary while the
other is moved.
[0157] The set of commands may also include one or more second
commands to reduce an extrusion flow rate of the extruder as the
extruder moves back along the first line and away from the
deposition platform. For example, when the extruder is a paste
extruder or syringe type extruder, the one or more second commands
may cause pressure applied to a plunger of the extruder to be
reduced as the extruder moves away from the deposition platform. As
another example, when the extruder is a filament-fed extruder, the
one or more second commands may cause a feed rate of the filament
to be reduced as the extruder moves away from the deposition
platform.
[0158] In a particular embodiment, the set of commands may be
executable to cause the 3D printer device to form a physical model
by depositing multiple lines of the material including the first
line. For example, depositing the multiple lines may include
forming a base layer of the material on the deposition platform and
stacking multiple layers of the material on the base layer. As
another example, depositing the multiple lines may include forming
a first stack of multiple layers of the material at a first
location relative to the deposition platform and after forming the
first stack, forming a second stack of multiple layers of the
material at a second location relative to the deposition platform.
In this example, the first stack may be formed to a height
determined based on a physical configuration of the 3D printer
device before the second stack is formed. The physical
configuration of the 3D printer device may include or correspond to
a distance between an extruder tip of the extruder and a support
member coupled to the extruder. To illustrate, in FIGS. 5-7, the
first stack 504 is formed by depositing a plurality of lines
(arranged as layers) on the deposition platform. After the first
stack 504 reaches the second height 522 (which is less that the
first height 520), the second stack 514 is formed. In some
embodiments, the first line forms at least a portion of a first
layer and at least a portion of a second layer, wherein the second
layer is stacked on the first layer, as illustrated in FIG. 5.
[0159] In a particular embodiment, the set of commands may be
executable to cause the 3D printer device to deposit multiple
layers of the material including the first line to form a first
portion of a physical model defining a non-planar surface and to
cause the 3D printer device to use a second extruder to deposit at
least one additional material on the non-planar surface to form a
second portion of the physical model. For example, after the
extruder 502 is used to deposit a first material to form the
non-planer surface 852 of FIG. 14, the extruder 802 may be used to
deposit a portion of the second material 808 on the non-planar
surface 852.
[0160] In a particular embodiment, the set of commands may be
executable to cause the 3D printer device to form the physical
model by stacking multiple layers of the material, where the 3D
model defines a void region within an area corresponding to at
least one layer of the multiple layers. In this embodiment, the set
of commands may cause the 3D printer device to form the at least
one layer as a set of polygons adjacent to a location corresponding
to the void region. For example, the set of polygons may be formed
such that no polygon of the set of polygons circumscribes the
location corresponding to the void region. To illustrate, as shown
in FIG. 4, when a slicer application identifies the void region 418
within the slice 414, the slicer application may form the set of
polygons 420, 422, 424, 426 that circumscribe the void region 418.
Thus, the set of commands 109 includes cause a physical model of
the slice 414 to be formed by applying lines to form physical
models of the polygons 420, 422, 424, 426.
[0161] FIG. 22 is a flowchart of a particular embodiment of a
method that may be performed by one or more devices or components
of the system 100 of FIG. 1. For example, the method 2200 may be
performed by the controller 141 of the 3D printer device executing
instructions from the memory 142. As another example, the method
2200 may be performed by the processor 103 of the computing device
102 executing instructions from the memory 104.
[0162] The method 2200 includes, at 2202, obtaining model data
representing a three-dimensional (3D) model of an object. For
example, the processor 103 of FIG. 1 may obtain the model data 107
by reading the model data 107 from the memory 104. As another
example, the controller 141 may obtain the model data 107 by
receiving the model data 107 via the communication interface
146.
[0163] The method 2200 includes, at 2204, processing the model data
to generate a set of commands to direct a 3D printer device to
extrude a material (e.g., a polymer) to form a physical model
associated with the object. The set of commands includes one or
more first commands to cause relative motion of an extruder of the
3D printer device and a deposition platform of the 3D printer
device during deposition of a portion of the material corresponding
to a line. The set of commands further includes one or more second
commands to adjust an extrusion rate of the extruder based on an
acceleration rate of the relative motion. For example, the set of
commands may be executable to cause an extrusion rate of one of
more of the extruders 130, 132, 134 to be adjusted based on an
acceleration rate of the extruder, as described further with
reference to FIG. 3B.
[0164] In some implementations, the one or more first commands
define a movement rate of the relative motion, such as a movement
rate of the extruder. In such implementations, the acceleration
rate of the relative motion may be determined based on settings of
the 3D printer device. For example, the settings 150 of FIG. 1 may
indicate a rate (or a maximum rate) at which the actuators 143 are
to change a velocity of the relative motion of the extruders 130,
132, 134 and the deposition platform. Alternately, in such
implementations, the acceleration rate of the relative motion may
be determined based on a hardware configuration of the 3D printer
device. For example, the memory 142 of FIG. 1 may include
information indicating a rate (or a maximum rate) at which the
actuators 143 are to change a velocity of the relative motion of
the extruders 130, 132, 134 and the deposition platform.
[0165] In a particular embodiment, the set of commands may be
executable to cause the 3D printer device to form a physical model
by depositing multiple lines of the material including the first
line. For example, depositing the multiple lines may include
forming a base layer of the material on the deposition platform and
stacking multiple layers of the material on the base layer. As
another example, depositing the multiple lines may include forming
a first stack of multiple layers of the material at a first
location relative to the deposition platform and after forming the
first stack, forming a second stack of multiple layers of the
material at a second location relative to the deposition platform.
In this example, the first stack may be formed to a height
determined based on a physical configuration of the 3D printer
device before the second stack is formed. The physical
configuration of the 3D printer device may include or correspond to
a distance between an extruder tip of the extruder and a support
member coupled to the extruder. To illustrate, in FIGS. 5-7, the
first stack 504 is formed by depositing a plurality of lines
(arranged as layers) on the deposition platform. After the first
stack 504 reaches the second height 522 (which is less that the
first height 520), the second stack 514 is formed. In some
embodiments, the first line forms at least a portion of a first
layer and at least a portion of a second layer, wherein the second
layer is stacked on the first layer, as illustrated in FIG. 5.
[0166] In a particular embodiment, the set of commands may be
executable to cause the 3D printer device to deposit multiple
layers of the material including the first line to form a first
portion of a physical model defining a non-planar surface and to
cause the 3D printer device to use a second extruder to deposit at
least one additional material on the non-planar surface to form a
second portion of the physical model. For example, after the
extruder 502 is used to deposit a first material to form the
non-planer surface 852 of FIG. 14, the extruder 802 may be used to
deposit a portion of the second material 808 on the non-planar
surface 852.
[0167] In a particular embodiment, the set of commands may be
executable to cause the 3D printer device to form the physical
model by stacking multiple layers of the material, where the 3D
model defines a void region within an area corresponding to at
least one layer of the multiple layers. In this embodiment, the set
of commands may cause the 3D printer device to form the at least
one layer as a set of polygons adjacent to a location corresponding
to the void region. For example, the set of polygons may be formed
such that no polygon of the set of polygons circumscribes the
location corresponding to the void region. To illustrate, as shown
in FIG. 4, when a slicer application identifies the void region 418
within the slice 414, the slicer application may form the set of
polygons 420, 422, 424, 426 that circumscribe the void region 418.
Thus, the set of commands 109 includes cause a physical model of
the slice 414 to be formed by applying lines to form physical
models of the polygons 420, 422, 424, 426.
[0168] The illustrations of the examples described herein are
intended to provide a general understanding of the structure of the
various implementations. The illustrations are not intended to
serve as a complete description of all of the elements and features
of apparatus and systems that utilize the structures or methods
described herein. Many other implementations may be apparent to
those of skill in the art upon reviewing the disclosure. Other
implementations may be utilized and derived from the disclosure,
such that structural and logical substitutions and changes may be
made without departing from the scope of the disclosure. For
example, method operations may be performed in a different order
than shown in the figures or one or more method operations may be
omitted. Accordingly, the disclosure and the figures are to be
regarded as illustrative rather than restrictive.
[0169] Moreover, although specific examples have been illustrated
and described herein, it should be appreciated that any subsequent
arrangement designed to achieve the same or similar results may be
substituted for the specific implementations shown. This disclosure
is intended to cover any and all subsequent adaptations or
variations of various implementations. Combinations of the above
implementations, and other implementations not specifically
described herein, will be apparent to those of skill in the art
upon reviewing the description.
[0170] The Abstract of the Disclosure is submitted with the
understanding that it will not be used to interpret or limit the
scope or meaning of the claims. In addition, in the foregoing
Detailed Description, various features may be grouped together or
described in a single implementation for the purpose of
streamlining the disclosure. Examples described above illustrate
but do not limit the disclosure. It should also be understood that
numerous modifications and variations are possible in accordance
with the principles of the present disclosure. As the following
claims reflect, the claimed subject matter may be directed to less
than all of the features of any of the disclosed examples.
Accordingly, the scope of the disclosure is defined by the
following claims and their equivalents.
* * * * *