U.S. patent application number 15/218309 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 | 20170052531 15/218309 |
Document ID | / |
Family ID | 58157351 |
Filed Date | 2017-02-23 |
United States Patent
Application |
20170052531 |
Kind Code |
A1 |
Minardi; John ; et
al. |
February 23, 2017 |
SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER
Abstract
A method include obtaining model data specifying a
three-dimensional (3D) model of an object. The method also includes
generating first machine instructions executable by a 3D printing
device to generate a first portion of a physical model of the
object by depositing material using a syringe extruder. The first
machine instructions indicate a first value of a pressure setting,
the pressure setting indicating a pressure to be applied to the
syringe extruder. The method also includes generating second
machine instructions executable by a 3D printing device to generate
a second portion of the physical model of the object by depositing
material using the syringe extruder. The second machine
instructions indicate a second value of the pressure setting, the
second value different from the first value.
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.: |
15/218309 |
Filed: |
July 25, 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: |
B29C 64/393 20170801;
B29C 64/106 20170801; B33Y 30/00 20141201; B33Y 50/02 20141201;
G05B 2219/49007 20130101; B29B 7/74 20130101; Y02P 90/265 20151101;
B29C 64/118 20170801; G05B 2219/35134 20130101; B29C 64/35
20170801; B29B 7/72 20130101; B33Y 10/00 20141201; G05B 19/4099
20130101; B29C 64/124 20170801 |
International
Class: |
G05B 19/4099 20060101
G05B019/4099; B33Y 10/00 20060101 B33Y010/00; B29C 67/00 20060101
B29C067/00; B33Y 50/02 20060101 B33Y050/02; B33Y 30/00 20060101
B33Y030/00 |
Claims
1. A method comprising: obtaining model data specifying a
three-dimensional (3D) model of an object; processing the model
data to generate a sliced model defining a plurality of layers to
be deposited to form a physical model of the object, the plurality
of layers including a first layer and a second layer, wherein the
second layer is above and in contact with the first layer, the
first layer including a first region corresponding to a first
material and a second region corresponding to a second material,
and the second layer including a third region corresponding to the
first material and a fourth region corresponding to the second
material; and generating machine instructions executable by a 3D
printing device to deposit a portion of the first material
corresponding to the first region and to the third region before
depositing a portion of the second material corresponding to the
second region and to the fourth region.
2. The method of claim 1, wherein depositing the portion of the
second material corresponding to the second region includes
positioning a tip of an extruder associated with the second
material below an upper surface of the first material.
3. A method comprising: obtaining model data specifying a
three-dimensional (3D) model of an object; generating first machine
instructions executable by a 3D printing device to generate a first
portion of a physical model of the object by depositing material
using a syringe extruder, wherein the first machine instructions
indicate a first value of a pressure setting, the pressure setting
indicating a pressure to be applied to the syringe extruder; and
generating second machine instructions executable by a 3D printing
device to generate a second portion of the physical model of the
object by depositing material using the syringe extruder, wherein
the second machine instructions indicate a second value of the
pressure setting, the second value different from the first
value.
4. The method of claim 3, wherein the pressure setting indicates a
setting of a pressure regulator that controls fluid pressure
applied to a plunger of the syringe extruder.
5. The method of claim 3, wherein the syringe extruder has a first
flowrate when the pressure setting has the first value and has a
second flowrate when the pressure setting has the second value, and
wherein the first flowrate is different from the second
flowrate.
6. The method of claim 3, wherein the first machine instructions
further include first instructions to cause the syringe extruder to
move at a first speed while depositing the material, and the second
machine instructions further include second instructions to cause
the syringe extruder to move at the first speed while depositing
the material.
7. The method of claim 3, wherein the first machine instructions
further include first instructions to cause the syringe extruder to
move at a first speed while depositing the material, and the second
machine instructions further include second instructions to cause
the syringe extruder to move at a second speed while depositing the
material, wherein the first speed is different from the second
speed.
8. The method of claim 3, wherein the first value of the pressure
setting is determined based on a first temperature associated with
the material, wherein the second value of the pressure setting is
determined based on a second temperature associated with the
material.
9. The method of claim 3, further comprising determining, based on
characteristics of the material, a flowrate-to-pressure
relationship of the material before generating the first machine
instructions.
10. The method of claim 9, wherein the flowrate-to-pressure
relationship of the material is determined based on a temperature
associated with the material.
11. The method of claim 3, wherein the first value of the pressure
setting is determined based on a first target line width of the
material, wherein the second value of the pressure setting is
determined based on a second target line width of the material,
wherein the first target line width is different from the second
target line width.
12. The method of claim 11, wherein the second target line width is
greater than the first target line width by a non-integer
multiple.
13. The method of claim 11, wherein the second target line width is
greater than the first target line width and is less than two times
the first target line width.
14. The method of claim 3, wherein the first value of the pressure
setting is determined based on a first target line height of the
material, wherein the second value of the pressure setting is
determined based on a second target line height of the material,
wherein the first target line height is different from the second
target line height.
15. The method of claim 14, wherein the second target line height
is greater than the first target line height by a non-integer
multiple.
16. The method of claim 14, wherein the second target line height
is greater than the first target height and is less than two times
the first target line height.
17. The method of claim 3, wherein a third portion of the physical
model is associated with a second material, wherein the third
portion of the physical model defines a first opening, and wherein
the first value of the pressure setting is selected to cause the
syringe extruder to, during a single pass, substantially fill the
first opening to form the first portion of the physical model.
18. The method of claim 17, wherein a fourth portion of the
physical model is associated with the second material, wherein the
fourth portion of the physical model defines a second opening, and
wherein the second value of the pressure setting is selected to
cause the syringe extruder to, during a single pass, substantially
fill the second opening to form the second portion of the physical
model.
19. The method of claim 18, wherein the first opening has a first
width, the second opening has a second width, and the first width
is different from the second width.
20. The method of claim 3, wherein a third portion of the physical
model is associated with a second material, wherein the third
portion of the physical model defines a first opening, and wherein,
during deposition of the first portion of the physical model, the
syringe extruder is offset from a wall of the first opening by an
offset distance, and the first value of the pressure setting is
selected to cause the syringe extruder to deposit a line of the
material having a line width equal to or greater than the offset
distance.
21. A computer-readable storage device storing instructions that
are executable by a processor to cause the processor to perform
operations comprising: obtaining model data specifying a
three-dimensional (3D) model of an object; processing the model
data to generate a sliced model defining a plurality of layers to
be deposited to form a physical model of the object, the plurality
of layers including a first layer and a second layer, wherein the
second layer is above and in contact with the first layer, the
first layer including a first region corresponding to a first
material and a second region corresponding to a second material,
and the second layer including a third region corresponding to the
first material and a fourth region corresponding to the second
material; and generating machine instructions executable by a 3D
printing device to deposit a portion of the first material
corresponding to the first region and to the third region before
depositing a portion of the second material corresponding to the
second region and to the fourth region.
22. A computer-readable storage device storing instructions that
are executable by a processor to cause the processor to perform
operations comprising: obtaining model data specifying a
three-dimensional (3D) model of an object; generating first machine
instructions executable by a 3D printing device to generate a first
portion of a physical model of the object by depositing material
using a syringe extruder, wherein the first machine instructions
indicate a first value of a pressure setting, the pressure setting
indicating a pressure to be applied to the syringe extruder; and
generating second machine instructions executable by a 3D printing
device to generate a second portion of the physical model of the
object by depositing material using the syringe extruder, wherein
the second machine instructions indicate a second value of the
pressure setting, the second value different from the first
value.
23. A computing device comprising: a processor; and a memory
accessible to the processor, the memory storing instructions that
are executable by the processor to cause the processor to perform
operations comprising: obtaining model data specifying a
three-dimensional (3D) model of an object; processing the model
data to generate a sliced model defining a plurality of layers to
be deposited to form a physical model of the object, the plurality
of layers including a first layer and a second layer, wherein the
second layer is above and in contact with the first layer, the
first layer including a first region corresponding to a first
material and a second region corresponding to a second material,
and the second layer including a third region corresponding to the
first material and a fourth region corresponding to the second
material; and generating machine instructions executable by a 3D
printing device to deposit a portion of the first material
corresponding to the first region and to the third region before
depositing a portion of the second material corresponding to the
second region and to the fourth region.
24. A computing device comprising: a processor; and a memory
accessible to the processor, the memory storing instructions that
are executable by the processor to cause the processor to perform
operations comprising: obtaining model data specifying a
three-dimensional (3D) model of an object; generating first machine
instructions executable by a 3D printing device to generate a first
portion of a physical model of the object by depositing material
using a syringe extruder, wherein the first machine instructions
indicate a first value of a pressure setting, the pressure setting
indicating a pressure to be applied to the syringe extruder; and
generating second machine instructions executable by a 3D printing
device to generate a second portion of the physical model of the
object by depositing material using the syringe extruder, wherein
the second machine instructions indicate a second value of the
pressure setting, the second value different from the first
value.
25. A three-dimensional (3D) printer device comprising: one or more
extruders configured to deposit a first material and a second
material on a deposition platform to generate a physical model of
an object, the physical model including a plurality of layers that
includes a first layer and a second layer, wherein the second layer
is above and in contact with the first layer, wherein the first
layer includes a first region corresponding to the first material
and a second region corresponding to the second material, and
wherein the second layer includes a third region corresponding to
the first material and a fourth region corresponding to the second
material; an actuator coupled to the one or more extruders, the
deposition platform, or a combination thereof; and a controller
coupled to the actuator, the controller configured to: cause the
one or more extruders to deposit a portion of the first material
corresponding to the first region and to the third region; and
after depositing the portion of the first material, cause the one
or more extruders to deposit a portion of the second material
corresponding to the second region and to the fourth region.
26. A three-dimensional (3D) printer device comprising: a syringe
extruder configured to deposit a material on a deposition platform
at a flowrate based on a pressure regulator setting; an actuator
coupled to the syringe extruder, to the pressure regulator, to the
deposition platform, or to a combination thereof; and a controller
coupled to the actuator, the controller configured to cause the
syringe extruder to deposit a first portion of the material at a
first flowrate to form a first portion of a physical model of an
object based on a first value of the pressure regulator setting and
to cause the syringe extruder to deposit a second portion of the
material at a second flowrate to form a second portion of the
physical model based on a second value of the pressure regulator
setting.
27. A method comprising: receiving machine instructions that enable
generating a physical model of an object, the physical model
including a plurality of layers that includes a first layer and a
second layer, wherein the second layer is above and in contact with
the first layer, wherein the first layer includes a first region
corresponding to a first material and a second region corresponding
to a second material, and wherein the second layer includes a third
region corresponding to the first material and a fourth region
corresponding to the second material; depositing, based on the
machine instructions, a portion of the first material corresponding
to the first region and to the third region; and after depositing
the portion of the first material, depositing, based on the machine
instructions, a portion of the second material corresponding to the
second region and to the fourth region.
28. A method comprising: receiving first machine instructions
associated with a first portion of a physical model of an object
and second machine instructions associated with a second portion of
the physical model, wherein the first machine instructions indicate
a first value of a pressure setting, the pressure setting
indicating a first pressure to be applied to a syringe extruder,
and wherein the second machine instructions indicate a second value
of the pressure setting, the second value different from the first
value; depositing, using the syringe extruder of a
three-dimensional (3D) printer device, a portion of a material at a
first flowrate to form the first portion based on the first machine
instructions; and depositing, using the syringe extruder, another
portion of the material at a second flowrate to form the second
portion based on the second machine instructions, the first
flowrate different from the second flowrate.
29. A method comprising: obtaining model data specifying a
three-dimensional (3D) model of an object, the 3D model including a
first portion corresponding to a first material and a second
portion corresponding to a second material; processing the model
data to generate a sliced model defining a plurality of layers to
be deposited to form a physical model of the object; identifying,
based on the sliced model, an elongated feature extending between
multiple layers of the plurality of layers and having, in each of
the multiple layers, cross-sectional dimensions that satisfy a
point-deposition criterion; and generating machine instructions
executable by a 3D printing device to, for a first layer of the
multiple layers, deposit a portion of the first material to define
an opening associated with the elongated feature and deposit a
portion of the second material within the opening according to a
point-deposition technique.
30. The method of claim 29, wherein the machine instructions
include instructions to translate a first extruder associated with
the first material along a first axis, along a second axis, or
both, to deposit the portion of the first material.
31. The method of claim 30, wherein the portion of the second
material is deposited according to a point-deposition technique
without translating a second extruder along the first axis and
without translating the second extruder along the second axis.
32. The method of claim 29, wherein the point-deposition technique
causes a quantity of the second material sufficient to fill the
opening to be deposited.
33. The method of claim 32, wherein the quantity of the second
material is determined based on a flowrate of the second
material.
34. The method of claim 32, wherein the second material is
deposited using a syringe extruder, and wherein generating machine
instructions to deposit the portion of the second material
according to the point-deposition technique includes determining a
pressure setting and an extrusion time to cause the syringe
extruder to deposit the quantity of the second material.
35. The method of claim 29, wherein a cross-section of the
elongated feature in the first layer of the physical model
corresponds to a cross-section of the opening in the first
layer.
36. The method of claim 29, wherein a cross-sectional area of the
elongated feature in the 3D model is less than a cross-sectional
area of the opening in the first layer.
37. The method of claim 29, further comprising, after identifying
the elongated feature, modifying the sliced model to increase a
cross-sectional area of the elongated feature in at least one layer
of the multiple layers.
38. The method of claim 37, wherein the cross-sectional area of the
elongated feature is increased based on a dimension associated with
an extruder of the 3D printing device, wherein the extruder is
associated with the second material.
39. The method of claim 29, wherein the machine instructions are
further executable by the 3D printing device to, before depositing
the portion of the second material within the opening, deposit at
least a second layer of the multiple layers, wherein the opening
extends between the first layer and the second layer, and wherein
the portion of the second material deposited within the opening is
sufficient to fill the opening extending between the first layer
and the second layer.
40. The method of claim 39, wherein the machine instructions cause
a tip of an extruder associated with the second material to be
positioned below a surface of the second layer during at least a
portion of the point-deposition technique.
41. The method of claim 39, wherein the machine instructions cause
a tip of an extruder associated with the second material to
translate in a direction perpendicular to a surface of the second
layer during at least a portion of the point-deposition
technique.
42. The method of claim 29, wherein the point-deposition criterion
is satisfied when an aspect ratio determined based on the
cross-sectional dimensions is less than an aspect ratio
threshold.
43. A computer-readable storage device storing instructions that
are executable by a processor to cause the processor to perform
operations comprising: obtaining model data specifying a
three-dimensional (3D) model of an object, the 3D model including a
first portion corresponding to a first material and a second
portion corresponding to a second material; processing the model
data to generate a sliced model defining a plurality of layers to
be deposited to form a physical model of the object; identifying,
based on the sliced model, an elongated feature extending between
multiple layers of the plurality of layers and having, in each of
the multiple layers, cross-sectional dimensions that satisfy a
point-deposition criterion; and generating machine instructions
executable by a 3D printing device to, for a first layer of the
multiple layers, deposit a portion of the first material to define
an opening associated with the elongated feature and deposit a
portion of the second material within the opening according to a
point-deposition technique.
44. A computing device comprising: a processor; and a memory
accessible to the processor, the memory storing instructions that
are executable by the processor to cause the processor to perform
operations comprising: obtaining model data specifying a
three-dimensional (3D) model of an object, the 3D model including a
first portion corresponding to a first material and a second
portion corresponding to a second material; processing the model
data to generate a sliced model defining a plurality of layers to
be deposited to form a physical model of the object; identifying,
based on the sliced model, an elongated feature extending between
multiple layers of the plurality of layers and having, in each of
the multiple layers, cross-sectional dimensions that satisfy a
point-deposition criterion; and generating machine instructions
executable by a 3D printing device to, for a first layer of the
multiple layers, deposit a portion of the first material to define
an opening associated with the elongated feature and deposit a
portion of the second material within the opening according to a
point-deposition technique.
45. 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, to the second extruder, to the deposition platform, or to
a combination thereof; and a controller coupled to the actuator,
the controller configured to: cause the first extruder to deposit a
portion of the first material to define an opening associated with
an elongated feature of a physical model of an object, wherein the
elongated feature extends between multiple layers of a plurality of
layers of the physical model and has, in each of the multiple
layers, a cross-sectional dimension that satisfies a
point-deposition criterion; and cause the second extruder to
deposit a portion of the second material to form a portion of the
elongated feature using a point-deposition technique, wherein the
point-deposition technique deposits the portion of the second
material within the opening.
46. A method comprising: receiving machine instructions that enable
generating a physical model of an object including an elongated
feature, wherein the elongated feature extends between multiple
layers of a plurality of layers of the physical model and has, in
each of the multiple layers, a cross-sectional dimension that
satisfies a point-deposition criterion; depositing, using a first
extruder of a three-dimensional (3D) printer device, a portion of a
first material to define an opening associated with the elongated
feature of the physical model; and depositing, using a second
extruder of the 3D printer device, a portion of a second material
to form a portion of the elongated feature according to a
point-deposition technique, wherein the point-deposition technique
causes the portion of the second material to be deposited within
the opening.
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 specifying a three-dimensional (3D) model of an object.
The method further includes processing the model data to generate a
sliced model defining a plurality of layers to be deposited to form
a physical model of the object. The plurality of layers include a
first layer and a second layer, where the second layer is above and
in contact with the first layer. The first layer includes a first
region corresponding to a first material and a second region
corresponding to a second material, and the second layer includes a
third region corresponding to the first material and a fourth
region corresponding to the second material. The method further
includes generating machine instructions executable by a 3D
printing device to deposit a portion of the first material
corresponding to the first region and to the third region before
depositing a portion of the second material corresponding to the
second region and to the fourth region.
[0005] In another particular implementation, a method includes
obtaining model data specifying a three-dimensional (3D) model of
an object and generating first machine instructions executable by a
3D printing device to generate a first portion of a physical model
of the object by depositing material using a syringe extruder. The
first machine instructions indicate a first value of a pressure
setting, the pressure setting indicating a pressure to be applied
to the syringe extruder. The method also includes generating second
machine instructions executable by the 3D printing device to
generate a second portion of the physical model of the object by
depositing material using the syringe extruder. The second machine
instructions indicate a second value of the pressure setting.
[0006] In a particular embodiment, a computer-readable storage
device stores instructions that are executable by a processor to
cause the processor to perform operations including obtaining model
data specifying a three-dimensional (3D) model of an object. The
operations also include processing the model data to generate a
sliced model defining a plurality of layers to be deposited to form
a physical model of the object, the plurality of layers including a
first layer and a second layer. The second layer is above and in
contact with the first layer. The first layer includes a first
region corresponding to a first material and a second region
corresponding to a second material. The second layer includes a
third region corresponding to the first material and a fourth
region corresponding to the second material. The operations also
include generating machine instructions executable by a 3D printing
device to deposit a portion of the first material corresponding to
the first region and to the third region before depositing a
portion of the second material corresponding to the second region
and to the fourth region.
[0007] In a particular embodiment, a computer-readable storage
device stores instructions that are executable by a processor to
cause the processor to perform operations including obtaining model
data specifying a three-dimensional (3D) model of an object. The
operations also include generating first machine instructions
executable by a 3D printing device to generate a first portion of a
physical model of the object by depositing material using a syringe
extruder. The first machine instructions indicate a first value of
a pressure setting. The pressure setting indicating a pressure to
be applied to the syringe extruder. The operations also include
generating second machine instructions executable by the 3D
printing device to generate a second portion of the physical model
of the object by depositing material using the syringe extruder.
The second machine instructions indicate a second value of the
pressure setting.
[0008] In a particular embodiment, a computing device includes a
processor and a memory accessible to the processor. The memory
stores instructions that are executable by the processor to cause
the processor to perform operations including obtaining model data
specifying a three-dimensional (3D) model of an object. The
operations also include processing the model data to generate a
sliced model defining a plurality of layers to be deposited to form
a physical model of the object. The plurality of layers include a
first layer and a second layer, where the second layer is above and
in contact with the first layer. The first layer includes a first
region corresponding to a first material and a second region
corresponding to a second material, and the second layer includes a
third region corresponding to the first material and a fourth
region corresponding to the second material. The operations also
include generating machine instructions executable by a 3D printing
device to deposit a portion of the first material corresponding to
the first region and to the third region before depositing a
portion of the second material corresponding to the second region
and to the fourth region.
[0009] In a particular embodiment, a computing device includes a
processor and a memory accessible to the processor. The memory
stores instructions that are executable by the processor to cause
the processor to perform operations including obtaining model data
specifying a three-dimensional (3D) model of an object. The
operations also include generating first machine instructions
executable by a 3D printing device to generate a first portion of a
physical model of the object by depositing material using a syringe
extruder. The first machine instructions indicate a first value of
a pressure setting, where the pressure setting indicates a pressure
to be applied to the syringe extruder. The operations also include
generating second machine instructions executable by the 3D
printing device to generate a second portion of the physical model
of the object by depositing material using the syringe extruder.
The second machine instructions indicate a second value of the
pressure setting.
[0010] In a particular embodiment, a three-dimensional (3D) printer
device includes one or more extruders configured to deposit a first
material and a second material on a deposition platform to generate
a physical model of an object. The physical model includes a
plurality of layers including a first layer and a second layer,
where the second layer is above and in contact with the first
layer. The first layer includes a first region corresponding to the
first material and a second region corresponding to the second
material, and the second layer includes a third region
corresponding to the first material and a fourth region
corresponding to the second material. The 3D printer device also
includes an actuator coupled to the one or more extruders, the
deposition platform, or a combination thereof. The 3D printer
device also includes a controller coupled to the actuator. The
controller is configured to cause the one or more extruders to
deposit a portion of the first material corresponding to the first
region and to the third region, after depositing the portion of the
first material, to cause the one or more extruders to deposit a
portion of the second material corresponding to the second region
and to the fourth region.
[0011] In a particular embodiment, a three-dimensional (3D) printer
device includes a syringe extruder configured to deposit a material
on a deposition platform at a flowrate based on a pressure
regulator setting. The 3D printer device also includes an actuator
coupled to the syringe extruder, to the pressure regulator, to the
deposition platform, or to a combination thereof. The 3D printer
device further includes a controller coupled to the actuator. The
controller is configured to cause the syringe extruder to deposit,
based on a first value of the pressure regulator setting, a first
portion of the material at a first flowrate to form a first portion
of a physical model and to cause the syringe extruder to deposit,
based on a second value of the pressure regulator setting, a second
portion of the material at a second flowrate to form a second
portion of the physical model.
[0012] In a particular embodiment, a method includes receiving
machine instructions that enable a 3D printer to generate a
physical model of an object. The physical model includes a
plurality of layers that includes a first layer and a second layer,
where the second layer is above and in contact with the first
layer. The first layer includes a first region corresponding to a
first material and a second region corresponding to a second
material, and the second layer includes a third region
corresponding to the first material and a fourth region
corresponding to the second material. The method also includes
depositing, based on the machine instructions, a portion of the
first material corresponding to the first region and to the third
region. The method further includes, after depositing the portion
of the first material, depositing, based on the machine
instructions, a portion of the second material corresponding to the
second region and to the fourth region.
[0013] In a particular embodiment, a method includes receiving
first machine instructions associated with a first portion of a
physical model of an object and second machine instructions
associated with a second portion of the physical model. The first
machine instructions indicate a first value of a pressure setting,
where the pressure setting indicates a first pressure to be applied
to a syringe extruder. The second machine instructions indicate a
second value of the pressure setting, where the second value
different from the first value. The method also includes
depositing, using the syringe extruder of a three-dimensional (3D)
printer device, a portion of a material at a first flowrate to form
the first portion based on the first machine instructions. The
method further includes depositing, using the syringe extruder,
another portion of the material at a second flowrate to form the
second portion based on the second machine instructions. The first
flowrate is different from the second flowrate.
[0014] In another particular implementation, a method includes
obtaining model data specifying a three-dimensional (3D) model of
an object. The 3D model includes a first portion corresponding to a
first material and a second portion corresponding to a second
material. The method also includes processing the model data to
generate a sliced model defining a plurality of layers to be
deposited to form a physical model of the object. The method
further includes identifying, based on the sliced model, an
elongated feature extending between multiple layers of the
plurality of layers and having, in each of the multiple layers,
cross-sectional dimensions that satisfy a point-deposition
criterion. The method also includes generating machine instructions
executable by a 3D printing device to, for a first layer of the
multiple layers, deposit a portion of the first material to define
an opening associated with the elongated feature and deposit a
portion of the second material within the opening according to a
point-deposition technique.
[0015] In a particular implementation, a computer-readable storage
device stores instructions that are executable by a processor to
cause the processor to perform operations including obtaining model
data specifying a three-dimensional (3D) model of an object. The 3D
model includes a first portion corresponding to a first material
and a second portion corresponding to a second material. The
operations also include processing the model data to generate a
sliced model defining a plurality of layers to be deposited to form
a physical model of the object. The operations further include
identifying, based on the sliced model, an elongated feature
extending between multiple layers of the plurality of layers and
having, in each of the multiple layers, cross-sectional dimensions
that satisfy a point-deposition criterion. The operations also
include generating machine instructions executable by a 3D printing
device to, for a first layer of the multiple layers, deposit a
portion of the first material to define an opening associated with
the elongated feature and deposit a portion of the second material
within the opening according to a point-deposition technique.
[0016] In a particular embodiment, a computing device includes a
processor and a memory accessible to the processor. The memory
stores instructions that are executable by the processor to cause
the processor to perform operations including obtaining model data
specifying a three-dimensional (3D) model of an object. The 3D
model includes a first portion corresponding to a first material
and a second portion corresponding to a second material. The
operations also include processing the model data to generate a
sliced model defining a plurality of layers to be deposited to form
a physical model of the object. The operations further include
identifying, based on the sliced model, an elongated feature
extending between multiple layers of the plurality of layers and
having, in each of the multiple layers, cross-sectional dimensions
that satisfy a point-deposition criterion. The operations also
include generating machine instructions executable by a 3D printing
device to, for a first layer of the multiple layers, deposit a
portion of the first material to define an opening associated with
the elongated feature and deposit a portion of the second material
within the opening according to a point-deposition technique.
[0017] In a particular embodiment, a three-dimensional (3D) printer
device includes a first extruder configured to deposit a first
material on a deposition platform and a second extruder configured
to deposit a second material on the deposition platform. The 3D
printer device also includes an actuator coupled to the first
extruder, to the second extruder, to the deposition platform, or to
a combination thereof. The 3D printer device also includes a
controller coupled to the actuator. The controller is configured to
cause the first extruder to deposit a portion of the first material
to define an opening associated with an elongated feature of a
physical model of an object. The elongated feature extends between
multiple layers of a plurality of layers of the physical model and
has, in each of the multiple layers, a cross-sectional dimension
that satisfies a point-deposition criterion. The controller is
further configured to cause the second extruder to deposit a
portion of the second material to form a portion of the elongated
feature according to a point-deposition technique.
[0018] In an embodiment, a method includes receiving machine
instructions that enable generating a physical model of an object
including an elongated feature, where the elongated feature extends
between multiple layers of a plurality of layers of the physical
model and has, in each of the multiple layers, a cross-sectional
dimension that satisfies a point-deposition criterion. The method
also includes depositing, using a first extruder of a
three-dimensional (3D) printer device, a portion of a first
material to define an opening associated with the elongated feature
of the physical model. The method further includes depositing,
using a second extruder of the 3D printer device, a portion of a
second material to form a portion of the elongated feature
according to a point-deposition technique, where the
point-deposition technique causes the portion of the second
material to be deposited within the opening.
[0019] Features, functions, and advantages described herein 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
[0020] FIG. 1 is a block diagram that illustrates a system that
includes a three-dimensional (3D) printing device, according to a
particular embodiment;
[0021] FIGS. 2A and 2B illustrate extruding material having
particular line widths by a 3D printing device, according to
particular embodiments;
[0022] FIGS. 3A, and 3B illustrate extruding material having
particular line heights by a 3D printing device, according to
particular embodiments;
[0023] FIG. 4 illustrate extruding material to fill an opening
according to particular embodiments;
[0024] FIG. 5 illustrate extruding material to fill an offset
distance according to particular embodiments;
[0025] FIGS. 6, 7, 8, 9, and 10 illustrate various stages during
modeling, slicing and printing of a physical model;
[0026] FIG. 11 is a flow chart of an example of a method that may
be performed by the system of FIG. 1;
[0027] FIG. 12 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0028] FIG. 13 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0029] FIG. 14 is a flow chart of another example of a method that
may be performed by the system of FIG. 1;
[0030] FIG. 15 is a flow chart of another example of a method that
may be performed by the system of FIG. 1; and
[0031] FIG. 16 is a flow chart of another example of a method that
may be performed by the system of FIG. 1.
DETAILED DESCRIPTION
[0032] 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 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 instructs 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.
[0033] 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,
causes 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).
[0034] 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.
[0035] In a particular embodiment, a 3D printer may include more
than one print head or more than one extruder. 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 syringe extruders include silicone
polymers, polyurethane, epoxy polymers. syringe extruders may be
especially useful to deposit materials that undergo curing upon
exposure to air or when mixed together (such as multi-component
epoxies).
[0036] 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.
[0037] When a 3D printer uses multiple extruders to deposit
multiple materials, determining when to switch between extruders
can be challenging. For example, if an object being printed is
formed of two different materials (e.g., a first material deposited
by a first extruder and a second material deposited by a second
extruder), a single layer of the object may include a region of the
first material and a region of the second material. Switching
extruders multiple times to print a single layer is time consuming
and inefficient. Accordingly, the slicer application may be
configured to reduce a number of tool swaps (i.e., changing from
using the first extruder to using the second extruder, or vice
versa). To illustrate, the region of the first material may be
deposited before the region of the second material.
[0038] Further, in some implementations, regions of multiple layers
of the first material may be deposited before the second material
is deposited in regions of the multiple layers. For example, a
first layer may include a first region associated with the first
material and a second region associated with the second material.
In this example, a second layer that is immediately adjacent to the
first layer may include a third region associated with the first
material and a fourth region associated with the second material.
In this example, portions of the first material may be deposited to
form the first region and the third regions. Subsequently, portions
of the second material may be deposited to form the second region
and the fourth region. Thus, some of the second material may be
deposited on a layer below a highest layer of the first material
that has been previously deposited.
[0039] In some instances, a 3D model may include a feature
associated with one material that extends through multiple layers
of the other material. For example, the feature may include a
conductive feature (e.g. a wire formed of a conductive material)
that is positioned such that it extends between multiple layers of
a non-conductive material (e.g., a matrix material). In this
example, the wire may have a relatively small cross-section in each
layer. Conventional deposition techniques move an extruder
laterally (e.g., in an X-Y plane) as material is extruded; however,
due to the small cross-section of wires, and other extended
features, lateral motion of the extruder may be inconvenient. In a
particular embodiment, such extended features may be formed
according to a point-deposition technique. To use the
point-deposition technique, one or more layers of the matrix
material may be deposited to form an opening (or hole). A second
material (e.g., the conductive material) may be deposited in the
opening according to the point-deposition technique. The
point-deposition technique may control a flow rate and dwell time
of the extruder such that enough of the second material is
deposited to substantially fill the opening. If multiple layers of
the matrix material are deposited before the second material is
deposited, an end of the extruder may be positioned with the
opening (e.g., below an upper layer of the matrix material). The
extruder may begin extruding the second material, and the extruder
may move vertically (e.g., along a Z-axis) relative to the physical
model being formed. For example, a deposition platform may be moved
away from the extruder. As another example, the extruder may be
moved away from the deposition platform. Thus, multiple layers of
the second material may be deposited together according to the
point-deposition technique. Depositing multiple layers of the
second material together may improve interlayer adhesion.
Additionally, if the second material is conductive, depositing
multiple layers of the second material together may improve
electrical properties of a wire formed using the second
material.
[0040] FIG. 1 illustrates a particular embodiment of a system 100
that includes a 3D printer device 101 and a computing device 102. A
communication interface 146 of the 3D printer device 101 may be
coupled, via a communications bus 170, to a communication interface
105 of the computing device 102. The bus 170 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.
[0041] In a particular embodiment, the computing device 102
includes a processor 103 and a memory 104. The memory 104 may
include a computer readable storage device (e.g., a physical,
hardware device, which is not merely a signal), such as a volatile
or non-volatile memory device. 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.
[0042] 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 170 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.
[0043] 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 and an
Nth printhead 115.
[0044] Although two particular printheads are illustrated in FIG.
1, in other embodiments, the 3D printer device 101 may include more
than two printheads or fewer than two printheads. Each printhead
113,115 includes a corresponding extruder with an extruder tip. For
example, the first printhead 113 includes a syringe extruder 130
having a tip 131, and the Nth printhead 115 includes an Nth
extruder 134 including a tip 135. The Nth extruder 134 may include
another syringe extruder or another type of extruder, such as a
filament-fed extruder.
[0045] The controller 141 may 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.
[0046] The controller 141 may also be coupled to a control system
associated with the syringe extruder 130. For example, the syringe
extruder 130 may include a plunger 132 that is movable to force
material through the tip 131. The plunger 132 may be pneumatically,
hydraulically, or mechanically controlled. For example, in the
implementation illustrated in FIG. 1, the plunger 132 is coupled to
a pressurized fluid source 164 via a pressure regulator 160 and a
valve 162. In this example, a position of the valve 162 (e.g., open
or closed) is controlled by the controller 141 to control when the
syringe extruder 130 extrudes material. To illustrate, to begin
deposition of the material, the controller 141 causes the valve 162
to be moved to an open position, and to stop deposition of the
material, the controller 141 causes the valve 162 to be moved to a
closed position. A pressure setting of the pressure regulator 160
may be controlled by the controller 141 to control an extrusion
rate (e.g., a material flowrate) of the syringe extruder 130. To
illustrate, to increase the flowrate, the pressure setting of the
pressure regulator 160 may be increased to apply more pressure to
the plunger 132. Conversely, to decrease the flowrate, the pressure
setting of the pressure regulator 160 may be decreased to apply
less pressure to the plunger 132. Although the valve 162 is
illustrated between the pressurized fluid source 164 and the
pressure regulator 160 in FIG. 1, in other implementations, the
pressure regulator 160 may be positioned between the valve 162 and
the pressurized fluid source 164.
[0047] The 3D printer device 101 may also include a memory 142
accessible to the controller 141. The memory 142 may include a
computer readable storage device (e.g., a physical, hardware
device, which is not merely a signal), such as a volatile or
non-volatile memory device. In a particular embodiment, the memory
142 includes 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, 135, or both. 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
one or more materials deposited by the extruders 130, 134.
[0048] The memory 142 may also include settings 150. The settings
150 may include control parameters or other values used by the
controller 141 to control components of the 3D printer device 101.
For example, the settings 150 may indicate a value of the pressure
setting for the pressure regulator 160. In other examples, the
settings 150 may indicate a target or actual deposition platform
temperature, extruder or extruder tip temperature, filament feed
rate, or other information. The settings 150 may be updated of
modified by a user (e.g., via a user interface, not shown), by the
computing device 102 (e.g., via the commands 109), or via feedback
or control input from one or more sensors of the 3D printer device
101 (such as a temperature sensor 133 associated with the first
printhead 113).
[0049] In a particular embodiment, the memory 142 may also include
pressure-flowrate data 152 that indicates a relationship between
pressure applied to the plunger 132 and a flowrate of the syringe
extruder 130. The pressure-flowrate data 152 may be temperature
dependent. To illustrate, the pressure-flowrate data 152 may
specify a first relationship between the pressure and the flowrate
associated with first temperature or temperature range, and may
specify a second relationship between the pressure and the flowrate
associated with second temperature or temperature range. In this
embodiment, the controller 141 may update the settings 150
occasionally or periodically based on a temperature indicated by
the temperature sensor 133. For example, the pressure setting of
the settings 150 may be updated when the temperature changes from
the first temperature to the second temperature.
[0050] The memory 142 may also include point-deposition technique
instructions 154. The point-deposition technique instruction 154
include instructions that enable formation features that have a
cross-section within a particular layer (or multiple layers) that
satisfy a point-deposition criterion (such as being too small to
extruder while moving the printheads 113, 115 in the X direction
138, in the Y direction 139, or both. Examples of point-deposition
techniques are described further with reference to FIGS. 6-10. The
point-deposition technique instructions 154 may be applied to
commands provided by an external computing device, such as the
computing device 102, in order to improve interlayer adhesion or
other properties (e.g., electrical properties) of small, low aspect
ratio features within a layer or extending between layers.
[0051] Accordingly, the 3D printer device 101 enables use of
multiple printheads 113, 115 with multiple distinct materials.
Further, the 3D printer device 101 includes data, settings and
instructions that improve printing using a syringe type extruder,
such as the syringe extruder 130. For example, the
pressure-flowrate data 152 may be used to determine a pressure
setting for the pressure regulator 160 based on, for example, a
target line width, a target line height, a temperature associated
with the first printhead 113, other information, or a combination
thereof. As another example, the point-deposition technique
instruction 154 may be used to control deposition by the syringe
extruder 130 of material to form small, low aspect ratio features
within a layer or extending between layers.
[0052] FIGS. 2A-2B illustrate use pressure (e.g. a pressure setting
of the pressure regulator 160) and velocity (e.g., a rate of motion
in the X direction 138, in the Y direction 139, in the Z direction
140, or in a combination thereof, such as during conformal printing
with concurrent motion in the X, Y and Z directions 138-140) to
control line width of material deposited by the syringe extruder
130 of FIG. 1. In particular, FIG. 2A illustrates line width of a
line 202 deposited at a constant velocity while changing the
pressure setting. FIG. 2B illustrates line width of a line 210
deposited at a constant pressure setting while changing the
velocity of motion of the syringe extruder 130.
[0053] In FIG. 2A, the pressure setting has a first value during a
first time 204 and has a second value during a second time 206. The
second value is greater than the first value; thus, the plunger 132
of the syringe extruder 130 is subject to higher pressure during
the second time 206 than during the first time 204. Due to the
pressure difference, the line 202 has a first line width during the
first time 204 and has a second line width during the second time
206. The first line width is less than the second line width
because, although the velocity of the syringe extruder 130 is
constant, the flowrate of material deposited by the syringe
extruder 130 during the second time 206 is greater than the
flowrate of material during the first time 204 as a result of the
increased pressure. The increased flowrate (with the same extruder
velocity) causes the material deposited during the second time 206
to spread out more than the material deposited during the first
time 204.
[0054] Further, the pressure setting has a third value during a
third time 208. The third value is less than the first value; thus,
the syringe extruder 130 is subject to less pressure during the
third time 208 than during the first time 204. Accordingly, during
the third time 208, the line 202 has a third line width that is
less than the first line width. In a particular embodiment, the
pressure-flowrate data 152 may include a table, a set of tables, an
algorithm, a set of algorithms, or other information that enables
the controller 141 to determine a value of the pressure setting
based on a target line width (e.g., a desired line width at a
particular time), a velocity of the syringe extruder 130, a
temperature associated with the syringe extruder 130, or a
combination thereof.
[0055] In FIG. 2B, the pressure is constant; however, the velocity
has a first value during a first time 212 and has a second value
during a second time 214. The second value is less than the first
value; thus, the syringe extruder 130 has a constant flowrate, but
a reduced velocity during the second time 214. Due to the velocity
difference, the line 210 has a first line width during the first
time 212 and has a second line width during the second time 214.
The first line width is less than the second line width. The
decreased velocity causes the material deposited during the second
time 214 to spread out more than the material deposited during the
first time 212.
[0056] Further, the velocity has a third value during a third time
216. The third value is greater than the first value. Accordingly,
during the third time 216, the line 210 has a third line width that
is less than the first line width. In a particular embodiment, the
pressure-flowrate data 152 may include information that enables the
controller 141 to determine a value of the velocity of the syringe
extruder 130 based on a target line width (e.g., a desired line
width at a particular time), a pressure setting of the pressure
regulator 160, a temperature associated with the syringe extruder
130, or a combination thereof.
[0057] FIGS. 3A-3B illustrate use pressure (e.g. a pressure setting
of the pressure regulator 160) and velocity (e.g., a rate of motion
in the X direction 138, in the Y direction 139, or a combination
thereof) to control line height of material deposited by the
syringe extruder 130 of FIG. 1. In particular, FIG. 3A illustrates
line height of a line 302 deposited at a constant velocity while
changing the pressure setting. FIG. 2B illustrates line width of a
line 310 deposited at a constant pressure setting while changing
the velocity of motion of the syringe extruder 130.
[0058] In FIG. 3A, the pressure setting has a first value during a
first time 304 and has a second value during a second time 306. The
second value is greater than the first value; thus, the plunger 132
of the syringe extruder 130 is subject to higher pressure during
the second time 306 than during the first time 304. Due to the
pressure difference, the line 302 has a first line height during
the first time 304 and has a second line height during the second
time 306. The first line height is less than the second line height
because, although the velocity of the syringe extruder 130 is
constant, the flowrate of material deposited by the syringe
extruder 130 during the second time 306 is greater than the
flowrate of material during the first time 304 as a result of the
increased pressure. The increased flowrate (with the same extruder
velocity) causes the material deposited during the second time 306
to pile up more than the material deposited during the first time
304
[0059] Further, the pressure setting has a third value during a
third time 308. The third value is less than the first value; thus,
the syringe extruder 130 is subject to less pressure during the
third time 308 than during the first time 304. Accordingly, during
the third time 308, the line 302 has a third line height that is
less than the first line height. In a particular embodiment, the
pressure-flowrate data 152 may include a table, a set of tables, an
algorithm, a set of algorithms, or other information that enables
the controller 141 to determine a value of the pressure setting
based on a target line height (e.g., a desired line height at a
particular time), a velocity of the syringe extruder 130, a
temperature associated with the syringe extruder 130, or a
combination thereof.
[0060] In FIG. 3B, the pressure is constant; however, the velocity
has a first value during a first time 312 and has a second value
during a second time 314. The second value is less than the first
value; thus, the syringe extruder 130 has a constant flowrate, but
a reduced velocity during the second time 314. Due to the velocity
difference, the line 310 has a first line height during the first
time 312 and has a second line height during the second time 314.
The first line height is less than the second line height. The
decreased velocity causes the material deposited during the second
time 314 to pile up more than the material deposited during the
first time 312.
[0061] Further, the velocity has a third value during a third time
316. The third value is greater than the first value. Accordingly,
during the third time 316, the line 310 has a third line height
that is less than the first line height. In a particular
embodiment, the pressure-flowrate data 152 may include information
that enables the controller 141 to determine a value of the
velocity of the syringe extruder 130 based on a target line height
(e.g., a desired line height at a particular time), a pressure
setting of the pressure regulator 160, a temperature associated
with the syringe extruder 130, or a combination thereof.
[0062] FIG. 4 illustrates several examples of using pressure,
velocity, or both, to control a quantity of material deposited at a
particular location (e.g., a line width, a line height, or both).
FIG. 4 illustrates the syringe extruder 130 depositing lines of
material within openings 404, 414, 424 formed in another material.
For example, the Nth extruder 134 of FIG. 1 may be used to deposit
a matrix material 402 to form a portion of an object corresponding
to a 3D model. The matrix material 402 may define the openings 404,
414, 424.
[0063] In a first example 400, the first opening 404 has a first
width. In the first example 400, the controller 141 of FIG. 1 may
set the pressure setting associated with the pressure regulator 160
to a first pressure value, and may control the actuators 143 to
achieve movement of the syringe extruder 130 at a first velocity
(e.g., in the X direction 138, in the Y direction 139, or a
combination thereof). The first pressure value and the first
velocity are selected to enable the syringe extruder 130 to deposit
at least a sufficient quantity of material to form a line 406 that
extends to each edge of the opening 404. For example, the first
line 406 may have a first line width 408 that is substantially
equal to a width of the opening 404.
[0064] In a second example 410, the second opening 414 has a second
width. The second width of the second opening 414 is greater than
the first width of the first opening 404. To deposit at least a
sufficient quantity of material to form a line 416 that extends to
each edge of the opening 414, the velocity, the flowrate, or both,
of the syringe extruder 130 may be controlled. For example, the
controller 141 of FIG. 1 may set the pressure setting associated
with the pressure regulator 160 to a second pressure value and may
control the actuators 143 to achieve movement of the syringe
extruder 130 at the first velocity. In this example, the second
pressure value is greater than the first pressure value used in the
first example 400.
[0065] Alternatively, the controller 141 of FIG. 1 may set the
pressure setting associated with the pressure regulator 160 to the
first pressure value and may control the actuators 143 to achieve
movement of the syringe extruder 130 at the third velocity. In this
example, the third velocity is less than the first velocity used in
the first example 400.
[0066] In a third example 420, the third opening 424 has a third
width. The third width of the third opening 424 is less than the
first width of the first opening 404. To deposit at least a
sufficient quantity of material to form a line 426 that extends to
each edge of the opening 424, the velocity, the flowrate, or both,
of the syringe extruder 130 may be controlled. For example, the
controller 141 of FIG. 1 may set the pressure setting associated
with the pressure regulator 160 to a third pressure value and may
control the actuators 143 to achieve movement of the syringe
extruder 130 at the first velocity. In this example, the third
pressure value is less than the first pressure value used in the
first example 400.
[0067] Alternatively, the controller 141 of FIG. 1 may set the
pressure setting associated with the pressure regulator 160 to the
first pressure value and may control the actuators 143 to achieve
movement of the syringe extruder 130 at the second velocity. In
this example, the second velocity is less than the first velocity
used in the first example 400.
[0068] Although three examples 400, 410, and 420 are illustrated in
FIG. 4, other examples are possible. To illustrate, both the
pressure and the velocity may be controlled to achieve a target
line width. Further, during formation of a single physical model,
different pressure values, different velocities, or both, may be
used to achieve different target line widths.
[0069] FIG. 5 illustrates another example of using pressure,
velocity, or both, to control a quantity of material deposited at a
particular location (e.g., a line width, a line height, or both).
FIG. 5 illustrates the syringe extruder 130 depositing lines of
material within an opening 500 formed in another material. For
example, the Nth extruder 134 of FIG. 1 may be used to deposit the
matrix material 402 to form a portion of an object corresponding to
a 3D model. The matrix material 402 may define the opening 500
(only a portion of which is illustrated in FIG. 5).
[0070] The tip of the syringe extruder 130 had an orifice through
which material is extruded. The orifice has a first dimension
(e.g., an inner diameter) that is different from a second dimension
(e.g., an outer diameter) of an outer surface of the tip of the
syringe extruder 130. Further, in some embodiments, the tip of the
syringe extruder 130 is tapered (as illustrated in FIG. 5).
Accordingly, the tip of the syringe extruder 130 may be positioned
at an offset distance 504 from a wall of the opening 500 when the
syringe extruder 130 is depositing material. Depositing material at
the offset distance 504 from the wall of the opening 500 may lead
to issues with the physical model. For example, if a line 508
deposited closest to the wall does not contact the wall, the
physical model material deposited by the syringe extruder 130 may
not adhere sufficiently to the material 402.
[0071] In the example illustrated in FIG. 5, the line 508 deposited
closest to the wall has a first line width 506, and other lines 512
deposited further from the wall have a second line width 510. The
first line width 506 and the second line width are controlled based
on pressure applied to the plunger 132 of the syringe extruder 130,
velocity of motion of the syringe extruder 130, or both. For
example, when forming the line 508 closest to the wall a higher
value of the pressure setting may be used than when forming the
other lines 512. Alternatively, or in addition, when forming the
line 508 closest to the wall a lower velocity of motion of the
syringe extruder 130 may be used than when forming the other lines
512. Thus, different pressure settings may be used to form a single
physical model or portions of a single layer of the single physical
model.
[0072] FIGS. 6-10 illustrate several aspects of forming a physical
model of an object corresponding to a 3D model using a syringe
extruder. Each of FIGS. 6-10 includes a perspective view and a
front view.
[0073] FIG. 6 illustrates 3D model 602 of an object. For example,
the 3D model 602 may be represented by the model data 107 of FIG.
1. In this example, the 3D model 602 may include one or more solid
body models formed using a 3D computer-aided design (CAD)
application, such as the 3D modeling application 106 of FIG. 1. The
3D model includes a first portion (a body 604) corresponding to a
first material and a second portion (e.g., a feature 606)
corresponding to a second material. For example the body 604 may
correspond to a matrix material (e.g., a non-conductive structural
polymer), and the feature 606 may correspond to a filler material
(e.g., a conductive polymer forming at least part of an electrical
interconnect).
[0074] FIG. 7 illustrates a sliced model 702 formed based on the 3D
model 602. For example, the sliced model 702 may include a
plurality of slices 708. The sliced model 702 may be formed by the
slicer application 108 based on the model data 107 representing the
3D model 602.
[0075] In FIG. 7, each slice corresponds to a layer to be printed
by a 3D printing device (such as the 3D printer device 101 of FIG.
1) to form a physical model of the object. Each of the slices may
include one or more regions, with each region corresponding to a
single material. For example, a first slice 710 (e.g., the bottom
slice in FIG. 7) may include only a single region, indicating that
a layer corresponding to the first slice 710 is to be printed
entirely of a first material. However, a second slice 712 (e.g., a
top slice in FIG. 7) may include two regions, i.e., a first region
704 corresponding to the first material and a second region 714
corresponding to a second material. Thus, printing the second slice
712 includes depositing a portion of the first material to form the
first region 704 and depositing a portion of the second material to
form the second region 714.
[0076] The second region 712 is a portion of a feature (e.g., the
electrical interconnect described with reference to FIG. 6) that
extends through multiple slices of the sliced model 702 (and
accordingly, when formed will extend through multiple layers of the
physical model of the object). The slicer application 108 may
analyze the feature to determine whether the feature satisfies a
point-deposition criterion. For example, if the feature has a
cross-sectional dimension (e.g., a length, a width, a diameter, an
aspect ratio, or a combination thereof) within one or more slices,
the feature may satisfy the point-deposition criterion. To
illustrate, the point-deposition criterion may be satisfied if the
feature has an aspect ratio that is less than an aspect ratio
threshold, has a diameter (or length) that is less than a length
threshold, has a cross-sectional area that is less than a
cross-sectional area threshold, or has a combination thereof (e.g.,
has an aspect ratio that is less than an aspect ratio threshold and
has a cross-sectional area that is less than a cross-sectional area
threshold). The point-deposition criterion may be determined based
on characteristics of the 3D printing device that will be used to
form a physical model of the sliced model 702. For example, for a
particular 3D printing device, such as the 3D printer device 101 of
FIG. 1, thresholds for the point-deposition criterion may be
selected based on a minimum reliable line length of the 3D printer
device 101. The minimum reliable line length refers to a length of
a smallest length of a line that can be deposited by the 3D
printing device while maintaining desired characteristics, such as
interlayer adhesion, electrical characteristics (e.g., if the
material being deposited in conductive), etc.
[0077] For example, a first part of the feature may extend along a
single slice and may have a first interlayer feature dimension 720.
In this example, a second part of the feature may extend more or
less vertically through several slices and may have a second
interlayer feature dimension 722. The first interlayer feature
dimension 720 may not satisfy the point-deposition criterion since
the first part has a large aspect ratio and a large length within
the single slice. However, the second interlayer feature dimension
722 may satisfy the point-deposition criterion in multiple slices
since the second part has a small aspect ratio and a small length
in each of the multiple slices.
[0078] FIG. 8 illustrates a modified sliced model 802 based on the
sliced model 702 of FIG. 7. The modified sliced model 802 may
include one or more modified slices 804, which are modified
relative to slices of the sliced model 702. In the example
illustrated in FIG. 8, the modified slices 804 are modified to
enable forming the second region 712 of FIG. 7 according to a point
deposition techniques.
[0079] For example, the tip 131 of the syringe extruder 130 may
have a tapering shape, as illustrated in FIG. 8. The second region
712 of the feature that extends through multiple slices in the
sliced model 702 of FIG. 7 has a shape 806 illustrated in FIG. 8.
The shape 806 of the second region 712 satisfies the
point-deposition criterion in each slice that is modified in FIG.
8. For example, the shape 806 is only slightly larger than an outer
dimension of the tip 131 of the syringe extruder.
[0080] In the example of FIG. 8, multiple slices have been modified
to accommodate the tip 131. For example, in the top seven slices of
FIG. 8, the shape 806 has been modified to provide an opening
sufficiently large for the tip 131 to extend within layers
corresponding to the slices (as illustrated in FIG. 9). Thus, the
modified slices 804 enable use of a point deposition technique in
which the tip 131 is positioned below an upper surface of a
physical model, and the tip 131 is used to extrude material while
moving vertically (e.g., in a Z direction 140, as illustrated in
FIGS. 9 and 10) rather than laterally (e.g. in the X direction 138,
the Y direction 139, or both).
[0081] FIG. 9 illustrates a first stage during formation of a
physical model 902 corresponding to the modified sliced model 802.
For example, a plurality of layers 908 of a first material 904 have
been deposited leaving an opening 910 in each layer that
corresponds to one of the modified slices 804. The opening 910 in
each layer is to accommodate the tip 131 and to receive a second
material 906 deposited according to a point-deposition technique.
In FIG. 9, the tip 131 is moved vertically (e.g., in the Z
direction) to insert the tip 131 into openings 910 within layers of
the first material 904.
[0082] FIG. 10 illustrates a second stage during formation of the
physical model 902 corresponding to the modified sliced model 802.
The second stage may be subsequent to the first stage illustrated
in FIG. 9. In the second stage, the tip 131 is moved vertically
(e.g., in the Z direction) while depositing the second material 906
to fill the opening in the layers of the first material.
[0083] For example, as illustrated in the callout of the
perspective view, the layers 908 may include a first layer 1002 and
a second layer 1004. The second layer 1004 may be positioned above
and in contact with the first layer 1002. The first layer 1002
includes a first region 1010 corresponding to a portion of the
first material 904 and a second region 1012 corresponding to a
portion of the second material 906. The second layer 1004 includes
a third region 1020 corresponding to a portion of the first
material 904 and a fourth region 1022 corresponding to a portion of
the second material 906. In the example illustrated in FIG. 10,
multiple layers of the first material 904 are deposited before the
second material 906 is deposited. To illustrate, the first region
1010 and the third region 1020 may be formed before the second
region 1012 and the fourth region 1022 are formed.
[0084] The openings in the layers of the first material 904 to
accommodate the tip 131 for a tapered shape. Accordingly, a
quantity of the second material 906 deposited in adjacent layers
(such as the first layer 1002 and the second layer 1004) may be
different. To illustrate, as the tip 131 moves in the Z direction,
the tip 131 deposits more of the second material 906 in each layer
than in a previous layer. Pressure applied to a plunger of the
syringe extruder or velocity of motion of the tip 131 may be used
to vary the quantity of the second material deposited in each
layer. For example, as the tip 131 is moved in the Z direction, the
pressure setting of the pressure regulator 160 may remain constant
and the rate of motion in the Z direction may change (e.g.,
decrease) over time. As another example, as the tip 131 is moved in
the Z direction, the pressure setting of the pressure regulator 160
may be changed (e.g., increased) and the rate of motion in the Z
direction may remain constant. As yet another example, as the tip
131 is moved in the Z direction, the pressure setting of the
pressure regulator 160 may be changed (e.g., increased) and the
rate of motion in the Z direction may be changed.
[0085] FIG. 11 is a flowchart of a particular embodiment of a
method 1100 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1100 may be performed by the controller 141 of the 3D printer
device 101 executing instructions from the memory 142. As another
example, the method 1100 may be performed by the processor 103 of
the computing device 102 executing instructions from the memory
104.
[0086] The method 1100 includes, at 1102, obtaining model data
specifying a three-dimensional (3D) model of an object. The 3D
model includes a first portion corresponding to a first material
and a second portion corresponding to a second material. For
example, the 3D model may correspond to the model data 107 of FIG.
1. As another example, the 3D model may include or correspond to
the 3D model 602 of and the feature corresponding to the second
portion may correspond to the feature 606. In some implementations,
the first material may include a matrix material (e.g., a
non-conductive material, such as a polymer), and the second
material may include a filler material (e.g., a conductive
material, such as a conductive polymer). Thus, the 3D model may
include a conductive features, such as a wire, formed of the second
material extending though portions of the first material.
[0087] The method 1100 includes, at 1104, processing the model data
to generate a sliced model defining a plurality of layers to be
deposited to form a physical model of the object. For example, the
sliced model may include or correspond to the sliced model 702 of
FIG. 7. In this example, the sliced model may include a plurality
of slices 708.
[0088] The method 1100 includes, at 1106, identifying, based on the
sliced model, an elongated feature extending between multiple
layers of the plurality of layers and having, in each of the
multiple layers, cross-sectional dimensions that satisfy a
point-deposition criterion. For example, the elongated feature may
correspond to or include the feature 706 that has the second
intralayer feature dimension 722. In some implementations, the
point-deposition criterion is satisfied when an aspect ratio
determined based on the cross-sectional dimensions is less than an
aspect ratio threshold.
[0089] In some implementations, after identifying the elongated
feature, the sliced model may be modified. For example, the slice
model may be modified to increase a cross-sectional area of the
elongated feature in at least one layer of the multiple layers. To
illustrate, the cross-sectional area of the elongated feature may
be increased based on a dimension associated with an extruder of
the 3D printing device, where the extruder is associated with the
second material. For example, in the sliced model 702 of FIG. 7,
the feature 706 has a first cross-section, which is modified to
generate the modified sliced model 802 of FIG. 8. The modified
sliced model 802 is used to form the layers 908 of FIG. 9, which
include openings to receive a portion of the second material to
form a physical model of the elongated features. In this example,
the cross-section of the elongated feature in the first layer of
the physical model 902 corresponds to a cross-section of the
opening in the first layer. Also, the cross-sectional area of the
feature 606 in the 3D model 602 is less than a cross-sectional area
of the opening 910 in the at least some of the layers 908. Thus, in
some layers, the sliced model 702 is modified to increase a
cross-sectional dimension associated with the feature.
[0090] The method 1100 includes, at 1108, generating machine
instructions executable by a 3D printing device to, for a first
layer of the multiple layers, deposit a portion of the first
material to define an opening associated with the elongated feature
and deposit a portion of the second material within the opening
according to a point-deposition technique. The machine instructions
may include or correspond to the commands 109 of FIG. 1. The
machine instructions may enable depositing a portion of the first
material (e.g., corresponding to the first region 704 of FIG. 7) to
define an opening corresponding the opening 808 of FIG. 8. The
machine instructions may also enable depositing a portion of the
second material within the opening as illustrated in FIG. 10.
[0091] In some implementations, the machine instructions include
instructions to translate a first extruder associated with the
first material along a first axis, along a second axis, or both, to
deposit the portion of the first material. For example, the machine
instruction may cause the one or more of the extruders 130, 134 of
FIG. 1 to move in the X direction 138, in the Y direction 139, or
both, while depositing the first material. In some such
implementations, the portion of the second material is deposited
according to a point-deposition technique without translating a
second extruder along the first axis and without translating the
second extruder along the second axis. To illustrate, the syringe
extruder 130 may deposit the second material according to the
point-deposition technique by extruding the second material while
stationary in the X direction 138 and in the Y direction 139;
however, the syringe extruder 130 may move relative to the
deposition platform 112 in the Z direction 140.
[0092] In some implementations, the point-deposition technique
causes a quantity of the second material sufficient to fill the
opening to be deposited. The quantity of the second material
deposited may be determined based on a flowrate of the second
material. To illustrate, the second material may dep be deposited
using the syringe extruder 130. In this illustrative example,
generating the machine instructions may include determining a
pressure setting and an extrusion time (or values of others of the
settings 150) to cause the syringe extruder 130 to deposit the
quantity of the second material. For example, as illustrated in
FIG. 10, the pressure setting, the velocity of motion of the tip
131 of the syringe extruder 130, or both, may be controlled to
substantially fill the opening 910 of FIG. 9 with the second
material 906.
[0093] In a particular implementation, the machine instructions may
cause the 3D printing device to deposit at least a second layer of
the multiple layers before depositing the portion of the second
material within the opening. To illustrate, in FIG. 9, regions 1010
and 1020 of the first and second layers 1002 and 1004,
respectively, are formed of the first material 904 before the
second material 906 is deposited in an opening 910 formed in the
first and second layers 1002 and 1004. Thus, the opening 910
extends between multiple layers, including the first layer and the
second layer. The syringe extruder 130 is used to deposit a portion
of the second material 906 in the opening 910 sufficient to fill
the opening 910. For example, as illustrated in FIGS. 9 and 10, the
machine instructions may cause the tip 131 of the syringe extruder
130 to be positioned below a surface of the layers of the first
material 904 during at least a portion of the point-deposition
technique. In this example, the tip 131 of the syringe extruder 130
may be translated in a direction perpendicular to a surface of the
layers of the first material 904 (e.g., in the Z direction) during
at least a portion of the point-deposition technique.
[0094] FIG. 12 is a flowchart of a particular embodiment of a
method 1200 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1200 may be performed by the 3D printer device 101 (or a one or
more components thereof).
[0095] The method 1200 includes, at 1202, receiving machine
instructions that enable generating a physical model of an object
including an elongated feature. The elongated feature extends
between multiple layers of a plurality of layers of the physical
model and has, in each of the multiple layers, a cross-sectional
dimension that satisfies a point-deposition criterion. For example,
the object may correspond to the sliced model 702 of FIG. 7, which
includes the feature 706, a portion of which extends through
multiple slices of the sliced model 702.
[0096] The method 1200 includes, at 1204, depositing, using a first
extruder of a three-dimensional (3D) printer device, a portion of a
first material to define an opening associated with the elongated
feature of the physical model. For example, the 3D printer device
101 of FIG. 1 may be used to deposit a portion of the first
material 904 of FIG. 9 in a manner that defines the opening 910
associate with at least a portion of the feature 706.
[0097] The method 1200 includes, at 1206, depositing, using a
second extruder of the 3D printer device, a portion of a second
material to form a portion of the elongated feature according to a
point-deposition technique. The point-deposition technique causes
the portion of the second material to be deposited within the
opening. For example, the tip 131 of the syringe extruder 130 may
be inserted into at least a portion of the opening 910 in the first
material 904 of FIG. 9. In this example, the syringe extruder 130
may deposit a portion of the second material 906 in the opening as
the syringe extruder 130 is moved in the Z direction (as
illustrated in FIG. 10).
[0098] FIG. 13 is a flowchart of a particular embodiment of a
method 1300 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1300 may be performed by the controller 141 of the 3D printer
device 101 executing instructions from the memory 142. As another
example, the method 1300 may be performed by the processor 103 of
the computing device 102 executing instructions from the memory
104.
[0099] The method 1300 includes, at 1302, obtaining model data
specifying a three-dimensional (3D) model of an object. For
example, the computing device 102 of the 3D printer device 101 of
FIG. 1 may receive the model data 107, which includes or
corresponds to a 3D model of an object. To illustrate, the model
data 107 may represent the 3D model 602 of FIG. 6.
[0100] The method 1300 includes, at 1304, processing the model data
to generate a sliced model defining a plurality of layers to be
deposited to form a physical model of the object, the plurality of
layers including a first layer and a second layer. The second layer
is above and in contact with the first layer, the first layer
including a first region corresponding to a first material and a
second region corresponding to a second material, and the second
layer including a third region corresponding to the first material
and a fourth region corresponding to the second material. For
example, model data representing the 3D model 602 of FIG. 6 may be
processed to generate the sliced model 702 of FIG. 7. As described
with reference to FIG. 10, the sliced model may include adjacent
slices (e.g., a first slice and a second slice) corresponding to
the first layer 1002 and the second layer 1004, respectively. The
first layer 1002 includes the first region 1010 corresponding to
the first material and includes the second region 1012
corresponding to the second material. Further, the second layer
1004 includes the third region 1020 corresponding to the first
material and includes the fourth region 1022 corresponding to the
second material.
[0101] The method 1300 includes, at 1306, generating machine
instructions executable by a 3D printing device to deposit a
portion of the first material corresponding to the first region and
to the third region before depositing a portion of the second
material corresponding to the second region and to the fourth
region. For example, as described with reference to FIG. 10, first
material may be deposited to form the first region 1010 and the
third region 1020 before second material is deposited to form the
second region 1012 and the fourth region 1022.
[0102] In some implementations, depositing the portion of the
second material corresponding to the second region includes
positioning a tip of an extruder associated with the second
material below an upper surface of the first material. For example,
as illustrated in FIG. 10, the tip 131 of the syringe extruder 130
may be inserted in the opening defined by layers of the first
material 904 to deposit the second material 906 below an upper
surface of the first material 904.
[0103] FIG. 14 is a flowchart of a particular embodiment of a
method 1400 that may be performed by one or more devices or
components of the system 100 of FIG. 1. For example, the method
1400 may be performed by the controller 141 of the 3D printer
device 101 executing instructions from the memory 142. As another
example, the method 1400 may be performed by the processor 103 of
the computing device 102 executing instructions from the memory
104.
[0104] The method 1400 includes, at 1402, obtaining model data
specifying a three-dimensional (3D) model of an object. For
example, the computing device 102 of the 3D printer device 101 of
FIG. 1 may receive the model data 107, which includes or
corresponds to a 3D model of an object. To illustrate, the model
data 107 may represent the 3D model 602 of FIG. 6.
[0105] The method 1400 includes, at 1404, generating first machine
instructions executable by a 3D printing device to generate a first
portion of a physical model of the object by depositing material
using a syringe extruder. The first machine instructions indicate a
first value of a pressure setting, the pressure setting indicating
a pressure to be applied to the syringe extruder. For example, the
pressure setting may include a value stored in the settings 150
that indicates a setting of the pressure regulator 160 that
controls fluid pressure applied to the plunger 132 of the syringe
extruder 130 of FIG. 1. The first machine instructions may include
a data field indicating the first value of the pressure setting.
Alternatively, the first machine instruction may include
information (such as a target flowrate, a target line width, a
target line height, etc.) that the controller 141 can use along
with the pressure-flowrate data 152 to determine the first value of
the pressure setting.
[0106] The method 1400 includes, at 1406, generating second machine
instructions executable by a 3D printing device to generate a
second portion of the physical model of the object by depositing
material using the syringe extruder. The second machine
instructions indicate a second value of the pressure setting, the
second value different from the first value. As with the first
value of the pressure setting, the second value of the pressure
setting may indicate a setting of the pressure regulator 160 and
may be included a data field of the second machine instruction or
may be derived from information in the second machine instructions
along with the pressure-flowrate data 152.
[0107] In some implementations, the controller 141, the computing
device 102, or another device may determine the
pressure-to-flowrate data 152 by determining a flowrate-to-pressure
relationship of the material. To illustrate, one or more test
prints may be performed by the 3D printer device 101 to determine
the flowrate-to-pressure relationship of the material. As another
example, data specifying the flowrate-to-pressure relationship
(e.g., rheology data) of the material may be provided to the
computing device 102, to the 3D printer device 101, or to both,
from an external source, such as a vendor of the material.
[0108] In some implementations, the flowrate-to-pressure
relationship may be temperature dependent. For example, during
operation, the 3D printer device 101 may determine a temperature
associated with the first printhead 113 based on output of the
temperature sensor 133. The temperature associated with the first
printhead 113 may correspond to or be correlated with the
temperature of the material. The temperature of the material may be
used to select (e.g., from a look up table) or calculate the
flowrate-to-pressure relationship of the material. In such an
implementation, the first value of the pressure setting may be
determined based on a first temperature associated with the
material, and the second value of the pressure setting may be
determined based on a second temperature (e.g., at a later time)
associated with the material.
[0109] In some implementations, the value of the pressure setting
may be determined (e.g., by the controller 141) based on target
characteristics of a line that is to be deposited. For example, the
first value of the pressure setting may be determined based on a
first target line width (or a first target line height) of the
material, and the second value of the pressure setting may be
determined based on a second target line width (or a second target
line height) of the material. The first target line width (or the
first target line height) may be different from the second target
line width (or the second target line height). For example, in some
circumstances, a larger (e.g., wider or taller) than normal line
may be deposited in a particular location (e.g., to fill a space
(as illustrated in FIG. 4) if the space is smaller than two
normal-sized lines, but larger than one normal sized line. In this
example, the second target line width (or the second target line
height) may be greater than the first target line width (or the
first target line height) but less than two times the first target
line width (or the first target line height). To illustrate, the
second target line width (or the second target line height) may be
greater than the first target line width (or the first target line
height) by a non-integer multiple. The pressure setting, velocity
of the extruder, or both, may be controlled to deposit the larger
than normal line.
[0110] In a particular embodiment, the syringe extruder 130 has a
first flowrate when the pressure setting has the first value and
has a second flowrate (different than the first flowrate) when the
pressure setting has the second value. In addition to or instead of
controlling the pressure setting, the velocity of motion of the
extruder may be controller to control characteristics (e.g., line
width or line height) of deposited material. For example, the first
machine instructions may include first instructions to cause the
syringe extruder 130 to move at a first speed while depositing the
material, and the second machine instructions may include second
instructions to cause the syringe extruder 130 to move at the first
speed while depositing the material. The first speed may be the
same as or different from the second speed.
[0111] In some implementations, the material deposited by the
syringe extruder 130 may be deposited within an opening (or set of
openings) formed in another material. For example, a third portion
of the physical model may be associated with a second material and
may define a first opening. In this example, the first value of the
pressure setting may be selected to cause the syringe extruder to,
during a single pass, substantially fill the first opening to form
the first portion of the physical model. Likewise, in this example,
a fourth portion of the physical model may be associated with the
second material and may define a second opening. The second value
of the pressure setting may be selected to cause the syringe
extruder to, during a single pass, substantially fill the second
opening to form the second portion of the physical model. The first
opening may have a first width that is the same as or different
from a second width of the second opening. To illustrate, as
described with reference to FIGS. 2A, 2B, 3A, 3B and 4, the
pressure setting, the velocity of motion of the extruder, or both,
may be varied to achieve various line widths (or line heights),
e.g., to substantially fill an opening.
[0112] In another example, the third portion of the physical model
(associated with the second material) may define an opening. During
deposition of a portion of the material to form the first portion
of the physical model, the syringe extruder may be offset from a
wall of the first opening by an offset distance, as illustrated in
FIG. 5. In this example, the first value of the pressure setting
may be selected to cause the syringe extruder to deposit a line of
the material having a line width equal to or greater than the
offset distance, such as the line width 506. In this example, the
second line width may correspond to the second line width 510,
which may be used to form other lines of the material in the
opening.
[0113] 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 3D printer device 101 (or one or more
components thereof).
[0114] The method 1500 includes, at 1502, receiving machine
instructions that enable generating a physical model of an object,
the physical model including a plurality of layers that includes a
first layer and a second layer. The second layer is above and in
contact with the first layer. The first layer includes a first
region corresponding to a first material and a second region
corresponding to a second material, and wherein the second layer
includes a third region corresponding to the first material and a
fourth region corresponding to the second material. For example,
the machine instructions may include or correspond to the commands
109 of FIG. 1. The machine instructions specify operations to form
a physical model of an object. For example, the object may
correspond to the 3D model 602 of FIG. 6. In this example, the 3D
model 602 may be sliced to form the sliced model 702 of FIG. 7. The
sliced model 702 may be modified to form the modified sliced model
802, which may be used to form machine instructions. The 3D printer
device 101 performing operations described by the machine
instructions may deposit material corresponding to a plurality of
layers 908, which includes the first layer 1002 and the second
layer 1004.
[0115] The method 1500 includes, at 1504, depositing, based on the
machine instructions, a portion of the first material corresponding
to the first region and to the third region. For example, the first
material 904 of FIG. 10 may be deposited to form the first region
1010 and the third region 1020.
[0116] The method 1500 includes, at 1502, after depositing the
portion of the first material, depositing, based on the machine
instructions, a portion of the second material corresponding to the
second region and to the fourth region. For example, the second
material 906 of FIG. 10 may be deposited to form the second region
1012 and the fourth region 1022.
[0117] 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 3D printer device 101 (or one or more
components thereof).
[0118] The method 1600 includes, at 1602, receiving first machine
instructions associated with a first portion of a physical model of
an object and second machine instructions associated with a second
portion of the physical model. The first machine instructions
indicates a first value of a pressure setting, the pressure setting
indicating a first pressure to be applied to a syringe extruder,
and the second machine instructions indicates a second value of the
pressure setting, the second value different from the first value.
For example, the machine instruction may include or correspond to
the commands 109 of FIG. 1. The machine instructions may specify
values of one or more of the settings 150. Alternately, the machine
instructions may include information that is used by the controller
141 to determine the values of the settings 150. To illustrate, the
machine instructions may include target line information, such as
flowrate information, line height information, line width
information, or other parameters related to flowrate. In this
illustrative example, the controller 141 may determine values of
various settings, such as a pressure setting, a temperature
setting, a velocity setting, etc., to achieve line parameters
specified by the target line information. The various settings may
be determined, for example, based on the pressure-flowrate data
152, based on the calibration data 148, or based on other
information.
[0119] The method 1600 includes, at 1604, depositing, using the
syringe extruder of a three-dimensional (3D) printer device, a
portion of a material at a first flowrate to form the first portion
based on the first machine instructions. For example, the syringe
extruder 130 may be used to deposit a first portion of a line
having a first line width as described with reference to FIGS. 2A
and 2B by setting a flowrate of the syringe extruder 130 (based on
a pressure setting of the pressure regulator 160) and a velocity of
motion of the syringe extruder 130. As another example, the syringe
extruder 130 may be used to deposit the first portion of the line
having a first line height as described with reference to FIGS. 3A
and 3B by setting a flowrate of the syringe extruder 130 (based on
a pressure setting of the pressure regulator 160) and a velocity of
motion of the syringe extruder 130.
[0120] The method 1600 includes, at 1606, depositing, using the
syringe extruder, another portion of the material at a second
flowrate to form the second portion based on the second machine
instructions, the first flowrate different from the second
flowrate. For example, the syringe extruder 130 may be used to
deposit a second portion of the line having a second line width as
described with reference to FIGS. 2A and 2B by setting a flowrate
of the syringe extruder 130 (based on a pressure setting of the
pressure regulator 160) and a velocity of motion of the syringe
extruder 130. As another example, the syringe extruder 130 may be
used to deposit the second portion of the line having a second line
height as described with reference to FIGS. 3A and 3B by setting a
flowrate of the syringe extruder 130 (based on a pressure setting
of the pressure regulator 160) and a velocity of motion of the
syringe extruder 130.
[0121] 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.
[0122] 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.
[0123] 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.
* * * * *