U.S. patent application number 16/134451 was filed with the patent office on 2019-08-01 for three dimensional printing.
The applicant listed for this patent is MARKFORGED, INC.. Invention is credited to Antoni S. Gozdz, Gregory Thomas Mark.
Application Number | 20190232550 16/134451 |
Document ID | / |
Family ID | 51581819 |
Filed Date | 2019-08-01 |
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United States Patent
Application |
20190232550 |
Kind Code |
A1 |
Mark; Gregory Thomas ; et
al. |
August 1, 2019 |
THREE DIMENSIONAL PRINTING
Abstract
Various embodiments related to three dimensional printers, and
reinforced filaments, and their methods of use are described. In
one embodiment, a void free reinforced filament is fed into an
extrusion nozzle. The reinforced filament includes a core, which
may be continuous or semi-continuous, and a matrix material
surrounding the core. The reinforced filament is heated to a
temperature greater than a melting temperature of the matrix
material and less than a melting temperature of the core prior to
extruding the filament from the extrusion nozzle.
Inventors: |
Mark; Gregory Thomas;
(Brookline, MA) ; Gozdz; Antoni S.; (Acton,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MARKFORGED, INC. |
Watertown |
MA |
US |
|
|
Family ID: |
51581819 |
Appl. No.: |
16/134451 |
Filed: |
September 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15206569 |
Jul 11, 2016 |
10076876 |
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16134451 |
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15179223 |
Jun 10, 2016 |
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15206569 |
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14222318 |
Mar 21, 2014 |
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15179223 |
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61907431 |
Nov 22, 2013 |
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61902256 |
Nov 10, 2013 |
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61883440 |
Sep 27, 2013 |
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61881946 |
Sep 24, 2013 |
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61880129 |
Sep 19, 2013 |
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61878029 |
Sep 15, 2013 |
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61847113 |
Jul 17, 2013 |
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61831600 |
Jun 5, 2013 |
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61815531 |
Apr 24, 2013 |
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61804235 |
Mar 22, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29B 15/14 20130101;
B29C 2948/92704 20190201; B33Y 40/00 20141201; B29C 2948/92904
20190201; B29C 48/154 20190201; B29C 69/001 20130101; B29C 70/384
20130101; B33Y 30/00 20141201; B29C 64/106 20170801; B29C
2948/92076 20190201; B29C 2948/92571 20190201; B33Y 10/00 20141201;
B29K 2101/12 20130101; B29C 48/92 20190201; B33Y 70/00 20141201;
B29K 2105/08 20130101; B29C 48/2528 20190201; B29C 64/209 20170801;
B29C 64/118 20170801; B29C 48/05 20190201 |
International
Class: |
B29C 64/106 20060101
B29C064/106; B29C 64/118 20060101 B29C064/118; B33Y 70/00 20060101
B33Y070/00; B33Y 10/00 20060101 B33Y010/00; B33Y 30/00 20060101
B33Y030/00; B33Y 40/00 20060101 B33Y040/00; B29B 15/14 20060101
B29B015/14; B29C 69/00 20060101 B29C069/00; B29C 70/38 20060101
B29C070/38; B29C 48/154 20060101 B29C048/154; B29C 48/92 20060101
B29C048/92 |
Claims
1.-104. (canceled)
105. A three-dimensional printer, comprising: a multi-element
printhead including: a central channel configured to receive a
first material; a first inlet transverse to the central channel,
the first inlet configured to receive a second material and feed
the second material into the central channel; and an outlet in
fluid communication with the central channel, wherein the
multi-element printhead is configured to: selectively combine the
first material and the second material within the central channel
in a first combination; and deposit, via the outlet, the first
combination of the first material and the second material on a
build surface in a first layer of a part.
106. The three-dimensional printer of claim 105, wherein in
combining the first material and the second material, the
multi-element printhead is further configured to mix the first
material and the second material.
107. The three-dimensional printer of claim 105, wherein in
combining the first material and the second material, the
multi-element printhead is further configured to coat the first
material with the second material by surrounding the first material
with the second material.
108. The three-dimensional printer of claim 105, wherein in
combining the first material and the second material, the
multi-element printhead is further configured to layer the first
material and the second material.
109. The three-dimensional printer of claim 105, wherein the
multi-element printhead is further configured to singly deposit,
via the outlet, the first material on the build surface in the
first layer.
110. The three-dimensional printer of claim 109, wherein the
multi-element printhead further comprises a second inlet transverse
to the central channel, the second inlet configured to receive a
third material and feed the third material into the central
channel.
111. The three-dimensional printer of claim 110, wherein the
multi-element printhead is further configured to: selectively
combine the first material, the second material, and the third
material within the central channel in a second combination; and
deposit, via the outlet, the second combination of the first
material, the second material, and the third material on the build
surface in the first layer.
112. The three-dimensional printer of claim 111, wherein in
combining the first material, the second material, and the third
material, the multi-element printhead is further configured to
layer the first material, the second material, and the third
material such that the second material is on a first side of the
first material and the third material is on a second side of the
first material.
113. The three-dimensional printer of claim 112, wherein the first
material is a core material.
114. The three-dimensional printer of claim 113, wherein the second
material is a matrix material.
115. The three-dimensional printer of claim 114, wherein the third
material is a soluble support material.
116. The three-dimensional printer of claim 111, further comprising
a cutting mechanism positioned at the outlet of the multi-element
printhead and configured to selectively cut one of the first
combination of the first material and the second material, the
singly deposited first material, and the second combination of the
first material, the second material, and the third material.
117. The three-dimensional printer of claim 105, further comprising
an air nozzle configured to pre-heat a print area of the build
surface prior to deposition of the first combination of the first
material and the second material on the print area.
118. The three-dimensional printer of claim 105, further comprising
an air nozzle configured to cool the deposited first combination of
the first material and the second material.
119. A method of additively manufacturing a part, the method
comprising: feeding a first material into a central channel of a
multi-element printhead; feeding a second material into the central
channel through a first inlet in the multi-element printhead, the
first inlet transverse to the central channel; selectively
combining the first material and the second material in the central
channel in a first combination; and depositing the first
combination of the first material and the second material on a
build surface in a first layer of the part.
120. The method according to claim 119, wherein combining the first
material and the second material includes mixing the first material
and the second material.
121. The method according to claim 119, wherein combining the first
material and the second material includes coating the first
material with the second material by surrounding the first material
with the second material.
122. The method according to claim 119, wherein combining the first
material and the second material includes layering the first
material and the second material.
123. The method according to claim 119 further comprising singly
depositing the first material in the first layer.
124. The method according to claim 123, further comprising feeding
a third material into the central channel through a second inlet in
the multi-element printhead, the second inlet transverse to the
central channel.
125. The method according to claim 124, further comprising:
selectively combining the first material, the second material, and
the third material within the central channel in a second
combination; and depositing the second combination of the first
material, the second material, and the third material on the build
surface in the first layer.
126. The method according to claim 125, wherein combining the first
material, the second material, and the third material includes
layering the first material, the second material, and the third
material such that the second material is on a first side of the
first material and the third material is on a second side of the
first material.
127. The method according to claim 125, further comprising
selectively cutting, at an outlet of the multi-element printhead,
one of the first combination of the first material and the second
material, the singly deposited first material, and the second
combination of the first material, the second material, and the
third material.
128. The method according to claim 119, further comprising
pre-heating a print area of the build surface prior to depositing
the first combination of the first material and the second material
on the print area.
129. The method according to claim 119, further comprising cooling
the deposited first combination of the first material and the
second material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/206,569, filed Jul. 11, 2016 [now U.S. Pat.
No. 10,076,876], which is a continuation of U.S. patent application
Ser. No. 15/179,223, filed Jun. 10, 2016 [Abandoned], the
disclosure of which is herein incorporated by reference in its
entirety. The Ser. No. 15/179,223 application is a continuation of
U.S. patent application Ser. No. 14/222,318, filed Mar. 21, 2014
[Abandoned], the disclosure of which is herein incorporated by
reference in its entirety. The Ser. No. 14/222,318 application
claims the benefit under 35 U.S.C. .sctn. 119(e) of U.S.
provisional application Ser. No. 61/804,235, filed Mar. 22, 2013
[Expired], U.S. provisional application Ser. No. 61/815,531, filed
Apr. 24, 2013 [Expired], U.S. provisional application Ser. No.
61/831,600, filed Jun. 5, 2013 [Expired], U.S. provisional
application Ser. No. 61/847,113, filed Jul. 17, 2013 [Expired],
U.S. provisional application Ser. No. 61/878,029, filed Sep. 15,
2013 [Expired], U.S. provisional application Ser. No. 61/880,129,
filed Sep. 19, 2013 [Expired], U.S. provisional application Ser.
No. 61/881,946, filed Sep. 24, 2013 [Expired], U.S. provisional
application Ser. No. 61/883,440, filed Sep. 27, 2013 [Expired],
U.S. provisional application Ser. No. 61/902,256, filed Nov. 10,
2013 [Expired], and U.S. provisional application Ser. No.
61/907,431, filed Nov. 22, 2013 [Expired], the disclosures of which
are incorporated by reference in their entirety.
FIELD
[0002] Aspects relate to three dimensional printing.
BACKGROUND
[0003] Since the initial development of three dimensional printing,
also known as additive manufacturing, various types of three
dimensional printing and printers for building a part layer by
layer have been conceived. For example, Stereolithography (SLA)
produces high-resolution parts. However, parts produced using SLA
typically are not durable and are also often not UV-stable and
instead are typically used for proof-of-concept work. In addition
to SLA, Fused Filament Fabrication (FFF) three dimensional printers
are also used to build parts by depositing successive filament
beads of acrylonitrile butadiene styrene (ABS), or a similar
polymer. In a somewhat similar technique, "towpregs" including
continuous fiber reinforced materials including a resin are
deposited in a "green state". Subsequently, the part is placed
under vacuum and heated to remove entrapped air voids present in
the deposited materials and fully cure the part. Another method of
additive manufacturing, though not considered three-dimensional
printing, includes preimpregnated (prepreg) composite construction
where a part is made by cutting sheets of fabric impregnated with a
resin binder into two-dimensional patterns. One or more of the
individual sheets are then layered into a mold and heated to
liquefy the binding resin and cure the final part. Yet another
method of (non-three-dimensional printing) composite construction
is filament winding which uses strands of composite (containing
hundreds to thousands of individual carbon strands for example)
that are wound around a custom mandrel to form a part. Filament
winding is typically limited to concave shapes due to the filaments
"bridging" any convex shape due to the fibers being under tension
and the surrounding higher geometry supporting the fibers so that
they do not fall into the underlying space.
SUMMARY
[0004] In one embodiment, a method for manufacturing a part
includes: feeding a void free core reinforced filament into an
extrusion nozzle, wherein the core reinforced filament comprises a
core and a matrix material surrounding the core; heating the core
reinforced filament to a temperature greater than a melting
temperature of the matrix material and less than a melting
temperature of the core; and extruding the core reinforced filament
to form the part.
[0005] In another embodiment, a filament for use with a three
dimensional printer includes a multifilament core and a matrix
material surrounding the multifilament core. The matrix material is
substantially impregnated into the entire cross-section of the
multifilament core, and the filament is substantially void
free.
[0006] In yet another embodiment, a method for manufacturing a
part, the method includes: feeding a filament into a heated
extrusion nozzle; and cutting the filament at a location at or
upstream from an outlet of the heated nozzle.
[0007] In another embodiment, a three dimensional printer includes
a heated extrusion nozzle including a nozzle outlet and a feeding
mechanism constructed and arranged to feed a filament into the
heated extrusion nozzle. The three dimensional printer also
includes a cutting mechanism constructed and arranged to cut the
filament at a location at, or upstream from, the heated nozzle
outlet.
[0008] In yet another embodiment, a heated extrusion nozzle
includes a nozzle inlet constructed and arranged to accept a
filament and a nozzle outlet in fluid communication with the nozzle
inlet. A cross-sectional area of the nozzle outlet transverse to a
path of the filament is larger than a cross-sectional area of the
nozzle inlet transverse to the path of the filament.
[0009] In another embodiment, a filament for use with a three
dimensional printer includes a core including a plurality of
separate segments extending in an axial direction of the filament
and a matrix material surrounding the plurality of segments. The
matrix material is substantially impregnated into the entire
cross-section of the core, and the filament is substantially
voidfree.
[0010] In yet another embodiment, a method includes: positioning a
filament at a location upstream of a nozzle outlet where a
temperature of the nozzle is below the melting temperature of the
filament: and displacing the filament out of the nozzle outlet
during a printing process.
[0011] In another embodiment, a method includes: feeding a filament
from a first channel sized and arranged to support the filament to
a cavity in fluid communication a nozzle outlet, wherein a
cross-sectional area of the cavity transverse to a path of the
filament is larger than a cross-sectional area of the first channel
transverse to the path of the filament.
[0012] In yet another embodiment, a method for forming a filament
includes: mixing one or more fibers with a first matrix material to
form a core reinforced filament; and passing the filament through a
circuitous path to impregnate the first matrix material into the
one or more fibers.
[0013] In another embodiment, a method includes: coextruding a core
reinforced filament and a coating matrix material to form an outer
coating on the core reinforced filament with the coating
material.
[0014] In yet another embodiment, a method for manufacturing a part
includes: feeding a filament into a heated extrusion nozzle;
extruding the filament from a nozzle outlet: and
[0015] applying a compressive force to the extruded filament with
the nozzle.
[0016] In another embodiment, a method for manufacturing a part
includes: depositing a first filament into a layer of matrix
material in a first desired pattern using a printer head; and
curing at least a portion of the matrix layer to form a layer of a
part including the deposited first filament.
[0017] It should be appreciated that the foregoing concepts, and
additional concepts discussed below, may be arranged in any
suitable combination, as the present disclosure is not limited in
this respect. Further, other advantages and novel features of the
present disclosure will become apparent from the following detailed
description of various non-limiting embodiments when considered in
conjunction with the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The accompanying drawings are not intended to be drawn to
scale. In the drawings, each identical or nearly identical
component that is illustrated in various figures may be represented
by a like numeral. For purposes of clarity, not every component may
be labeled in every drawing. In the drawings:
[0019] FIG. 1 is a schematic representation of a three dimensional
printing system using a continuous core reinforced filament:
[0020] FIG. 2 is a representative flow chart of a three dimensional
printing process;
[0021] FIG. 3A is a schematic representation of a continuous core
reinforced filament including a solid continuous core and
surrounding thermoplastic resin with a smaller proportion of solid
continuous core;
[0022] FIG. 3B is a schematic representation of a continuous core
reinforced filament including a solid continuous core surrounded by
thermoplastic resin with a larger proportion of solid continuous
core;
[0023] FIG. 3C is a schematic representation of a continuous core
reinforced filament including a multifilament continuous core
surrounded by thermoplastic resin with a smaller proportion of the
multifilament continuous core:
[0024] FIG. 3D is a schematic representation of a continuous core
reinforced filament including a multifilament continuous core
surrounded by thermoplastic resin with a large proportion of the
multifilament continuous core;
[0025] FIG. 3E is a schematic representation of a continuous core
reinforced filament including a multifilament continuous core
including elements with electrical, optical, or fluidic
properties;
[0026] FIG. 4 is a schematic representation of a prior art nozzle
and a towpreg including voids;
[0027] FIG. 5 is a schematic representation of fiber bunching
within a prior art nozzle;
[0028] FIG. 6A is a schematic representation of a divergent nozzle
utilized in some embodiments of the printing system;
[0029] FIG. 6B is a schematic representation of a straight nozzle
utilized in some embodiments of the printing system:
[0030] FIG. 6C is a schematic representation of a rounded tip
nozzle utilized in some embodiments of the printing system;
[0031] FIG. 7 is a schematic representation of a prior art three
dimensional printing system:
[0032] FIG. 8 is a schematic representation of a three dimensional
printing system including a cutting mechanism and a printing
process bridging an open space;
[0033] FIG. 9 is a schematic representation of a part formed by the
three-dimensional printing system and/or process that includes an
enclosed open space;
[0034] FIG. 10 is a schematic representation of a three-dimensional
printing system including a guide tube;
[0035] FIG. 11 is a photograph of a three dimensional printing
system including a guide tube:
[0036] FIG. 12A is a schematic representation of a shear cutting
head with optional indexing positions;
[0037] FIG. 12B is a schematic representation of the shear cutting
head of FIG. 11A in a second indexing position:
[0038] FIG. 13 is a schematic representation of a multi-nozzle
print head including shear cutting;
[0039] FIG. 14A is a schematic representation of a nozzle:
[0040] FIG. 14B is a schematic representation of a nozzle having a
rounded outlet;
[0041] FIG. 14C is a schematic representation of another nozzle
having a rounded outlet;
[0042] FIG. 15A is a schematic cross-sectional view of a cutting
mechanism integrated with a nozzle tip;
[0043] FIG. 15B is a schematic cross-sectional view of the cutting
mechanism integrated with a nozzle tip depicted in FIG. 14A rotated
90.degree.;
[0044] FIG. 15C is a bottom view of one embodiment of a cutting
mechanism integrated with a nozzle tip;
[0045] FIG. 15D is a bottom view of one embodiment of a cutting
mechanism integrated with a nozzle tip;
[0046] FIG. 16 is a schematic cross-sectional view of a cutting
mechanism integrated with a nozzle tip:
[0047] FIG. 17A is a schematic representation of a
three-dimensional printing system applying a compaction pressure
during part formation:
[0048] FIG. 17B is a schematic representation of a continuous core
reinforced filament to be utilized with the printing system prior
to deposition;
[0049] FIG. 17C is a schematic representation of the continuous
core reinforced filament and surrounding beads of materials after
deposition using compaction pressure:
[0050] FIG. 18A is a schematic representation of a prior art
nozzle;
[0051] FIG. 18B is a schematic representation of a divergent
nozzle:
[0052] FIG. 18C is a schematic representation of the divergent
nozzle of FIG. 18B shown in a feed forward cleaning cycle;
[0053] FIG. 19A is a schematic representation of a continuous core
filament being printed with a straight nozzle;
[0054] FIG. 19B is a schematic representation of a green towpreg
being printed with a straight nozzle:
[0055] FIGS. 19C-19E are schematic representations of a continuous
core filament being stitched and printed with a divergent
nozzle;
[0056] FIG. 20A is a schematic representation of a multi-material
nozzle with a low friction cold feeding zone:
[0057] FIG. 20B is a schematic representation of a slightly
convergent nozzle including a low friction cold feeding zone;
[0058] FIG. 21A is a schematic representation of a prior art
nozzle:
[0059] FIGS. 21B-21D represent various embodiments of nozzle
geometries;
[0060] FIG. 22 is a schematic representation of an anti-drip nozzle
and pressure reduction system;
[0061] FIG. 23A is a schematic representation of a semi-continuous
core filament positioned within a nozzle;
[0062] FIG. 23B is a schematic representation of a semi-continuous
core filament with overlapping strands positioned within a
nozzle;
[0063] FIG. 23C is a schematic representation of a semi-continuous
core filament with aligned strands and positioned within a
nozzle:
[0064] FIG. 24A is a schematic representation of a multifilament
continuous core;
[0065] FIG. 24B is a schematic representation of a semi-continuous
core filament with offset strands;
[0066] FIG. 24C is a schematic representation of a semi-continuous
core filament with aligned strands;
[0067] FIG. 24D is a schematic representation of a semi-continuous
core filament with aligned strands and one or more continuous
strands;
[0068] FIG. 25 is a schematic representation of a fill pattern
using a semi-continuous core filament:
[0069] FIG. 26 is a schematic representation of multiple printed
layers formed by the three-dimensional printing system and/or
process with the different layers and different portions of the
layers including different fiber directions;
[0070] FIG. 27A is a schematic representation of a three
dimensional printing process for forming a component in a first
orientation;
[0071] FIG. 27B is a schematic representation of a fixture to use
with the part of FIG. 27A;
[0072] FIG. 27C is a schematic representation of a three
dimensional printing process for forming a component on the part of
FIG. 27A in a second orientation;
[0073] FIG. 28A is a schematic representation of a three
dimensional printing process using a multiaxis system in a first
orientation;
[0074] FIG. 28B is a schematic representation of forming a
component in another orientation on the part of FIG. 28A;
[0075] FIG. 29 is a schematic representation of a three dimensional
printing system using a continuous core reinforced filament;
[0076] FIG. 30A is a schematic representation of a part including a
shell applied to the sides using a three dimensional printing
process:
[0077] FIG. 30B is a schematic representation of a part including a
shell applied to the top and sides using a three-dimensional
printing process;
[0078] FIG. 30C is a schematic representation of a part including a
shell that has been offset from an underlying supporting
surface;
[0079] FIG. 30D is a schematic representation of a part formed with
a fill material;
[0080] FIG. 30E is a schematic representation of a part formed with
composite material extending inwards from the corners and polymer
fill in the interior:
[0081] FIG. 30F is a schematic representation of a part formed with
composite material extending inwards from the corners and polymer
fill in the interior;
[0082] FIG. 30G is a schematic representation of a part formed with
composite material extending inwards from the corners and polymer
fill in the interior;
[0083] FIG. 31A is a schematic representation of an airfoil formed
with discrete subsections including fiber orientations in the same
direction;
[0084] FIG. 31B is a schematic representation of an airfoil formed
with discrete subsections including fiber orientations in different
directions;
[0085] FIG. 31C is a schematic representation of an airfoil formed
with discrete subsections and a shell formed thereon:
[0086] FIG. 32 is a schematic representation of a three dimensional
printing system including a print arm and selectable printer
heads;
[0087] FIG. 33 is a schematic representation of a multi-element
printer head for use in the printing system;
[0088] FIG. 34 is a schematic representation of a stereolithography
three dimensional printing process including deposited reinforcing
fibers;
[0089] FIG. 35 is a schematic representation of a stereolithography
three dimensional printing process including deposited reinforcing
fibers:
[0090] FIG. 36 is a schematic representation of a three dimensional
printed part including incorporated printed components with
different functionalities:
[0091] FIG. 37 is a schematic representation of a three dimensional
printing system being used to form multiple layers in a printed
circuit board;
[0092] FIG. 38 is a schematic representation of a three dimensional
printing system being used to fill various voids in a printed
circuit board with solder or solder paste;
[0093] FIG. 39 is a schematic representation of the print circuit
board of FIG. 38 after the formation of vias and contact pads;
[0094] FIG. 40A is a schematic representation of a printed part
including a hole drilled therein:
[0095] FIG. 40B is a schematic representation of a printed part
including a reinforced hole formed therein;
[0096] FIG. 40C is a schematic representation of a printed part
including a reinforced hole formed therein;
[0097] FIG. 41A is a schematic representation of a composite part
formed using three-dimensional printing methods; and
[0098] FIG. 41B is a scanning electron microscope image of a
reinforcing carbon fiber and perpendicularly arranged carbon
nanotubes;
[0099] FIG. 42 is a schematic representation of a circuitous path
impregnation system
[0100] FIG. 43A is a schematic representation of an incoming
material with comingled tows;
[0101] FIG. 43B is a schematic representation of the material of
FIG. 43A after impregnation;
[0102] FIG. 44A is a schematic representation of an offset roller
impregnation system;
[0103] FIG. 44B is a schematic representation of the roller
impregnation system of FIG. 44A in an optional loading
configuration:
[0104] FIG. 45 is a schematic representation of an impregnation
system combined with a vacuum impregnation nozzle;
[0105] FIG. 46 is a schematic representation of an impregnation
system integrated with a printing nozzle;
[0106] FIG. 47 is a schematic representation of a printing nozzle
including a circuitous path impregnation system;
[0107] FIG. 48 is a schematic representation of a multi-nozzle
three-dimensional printer;
[0108] FIG. 49A is a schematic representation of a co-extrusion
process to form a continuous core reinforced filament and an
optional outer coating;
[0109] FIG. 49B is a schematic representation of a starting
material used in the process depicted in FIG. 49A:
[0110] FIG. 49C is a schematic representation of a starting
material used in the process depicted in FIG. 49A;
[0111] FIG. 49D is a schematic representation of one embodiment of
a material after impregnation using the process depicted in FIG.
49A;
[0112] FIG. 49E is a schematic representation of one embodiment of
a material after impregnation using the process depicted in FIG.
49A;
[0113] FIG. 49F is a schematic representation of one embodiment of
a material after impregnation using the process depicted in FIG.
49A:
[0114] FIG. 49G is a schematic representation of one embodiment of
a material including an optional outer coating using the process
depicted in 49A;
[0115] FIG. 49H is a schematic representation of one embodiment of
a material including an optional outer coating using the process
depicted in 49A;
[0116] FIG. 49I is a schematic representation of one embodiment of
a material including an optional outer coating using the process
depicted in 49A;
[0117] FIG. 50A is a schematic representation of a co-extrusion
process to form a continuous core reinforced filament and an
optional outer coating:
[0118] FIG. 50B is a schematic representation of a starting
material used in the process depicted in FIG. 50A;
[0119] FIG. 50C is a schematic representation of a starting
material used in the process depicted in FIG. 49A:
[0120] FIG. 50D is a schematic representation of a starting
material after being spread out using the process depicted in FIG.
50A;
[0121] FIG. 50E is a schematic representation of one embodiment of
a material after impregnation using the process depicted in FIG.
50A;
[0122] FIG. 50F is a schematic representation of one embodiment of
a material after shaping using the process depicted in FIG.
50A:
[0123] FIG. 50G is a schematic representation of one embodiment of
a material after shaping using the process depicted in FIG.
50A;
[0124] FIG. 50H is a schematic representation of one embodiment of
a material after shaping using the process depicted in FIG. 50A;
and
[0125] FIG. 50I is a schematic representation of one embodiment of
a material including an optional outer coating using the process
depicted in 50A.
DETAILED DESCRIPTION
[0126] The inventors have recognized that one of the fundamental
limitations associated with typical additive manufacturing methods
is the strength and durability of the resulting part. For example.
Fused Filament Fabrication results in a part exhibiting a lower
strength than a comparable injection molded part. Without wishing
to be bound by theory, this reduction in strength is due to weaker
bonding between the adjoining strips of deposited material (as well
as air pockets and voids) as compared to the continuous and
substantially void free material formed, for example, during
injection molding. The inventors have also recognized that the
prepreg composite construction methods using a sheet-based approach
to form a three dimensional part are both time consuming and
difficult to handle resulting in higher expenses. Further, bending
such sheets around curves, a circle for example, may cause the
fibers to overlap, buckle, and/or distort resulting in undesirable
soft spots in the resultant component. With regards to three
dimensional printers using "towpregs" or "tows" including
reinforcing fibers and a resin, the inventors have noted that the
prior art deposited materials are often difficult to load in the
machine, and further difficult to feed through the print head, due
to their extremely flexible, and usually high-friction (sticky)
initial state. Further, these green materials tend to entrap air
and include air voids. Thus, without a subsequent vacuum and
heating step, the resultant part also contains voids, and is
substantially weaker than a traditional composite part constructed
under a vacuum. Therefore, the additional steps associated with
preparing a towpreg slow down the printing process and result in
the entrapment of ambient air.
[0127] Due to the limitations associated with typical three
dimensional printing systems noted above, the inventors have
recognized a need to improve the strength of three dimensional
printed composites. Further, there is a need for additive
manufacturing construction techniques that allow for greater speed:
removal or prevention of entrapped air in the deposited material:
reduction of the need for subsequent vacuuming steps; and/or
correct and accurate extrusion of the composite core material. The
inventors have also recognized that it is desirable to provide the
ability to deposit fibers in concave shapes, and/or construct
discrete features on a surface or composite shell.
[0128] In view of the above, the inventors have recognized the
benefits associated with providing a three dimensional printing
system that prints structures using a substantially void-free
preimpregnated (prepreg) material, or that is capable of forming a
substantially void free material for use in the deposition process.
For example, in one embodiment, a three dimensional printer uses a
continuous core reinforced filament including a continuous
multifilament core material with multiple continuous strands that
are preimpregnated with a thermoplastic resin that has already been
"wicked" into the strands, such a preimpregnated material is then
used to form a three dimensional structure. Due to the
thermoplastic resin having already wicked into the strands, the
material is not "green" and is also rigid, low-friction, and
substantially void free. In another embodiment, a solid continuous
core is used and the thermoplastic resin wets the solid continuous
core such that the resulting continuous core reinforced filament is
also substantially void free. Additionally, embodiments in which a
semi-continuous core is used in which a core extending through the
length of a material is sectioned into a plurality of portions
along the length is also contemplated. Such an embodiment may
include either a solid core or multiple individual strands that are
either evenly spaced from one another or include overlaps as the
disclosure is not so limited. In either case, such a core material
may also be preimpregnated or wetted as noted above. A
substantially void free material may have a void percentage that is
less than about 1%, 2%, 3%, 4%, 5%, 10%, 13%, or any other
appropriate percentage. For example, the void free material may
have a void percentage that is between about 1% and 5%.
Additionally, due to the processing methods described below, parts
printed using the above-noted void free material may also exhibit
void percentages less than about 1%, 2%, 3%, 4%, 5%. 10%, or
13%.
[0129] While preimpregnated materials are discussed above, in one
embodiment, a solid continuous core filament may be selectively
combined with a resin in a nozzle outlet. Without wishing to be
bound by theory, due to the regular and well-defined geometry of
the solid core, the resin evenly coats the core and the resulting
deposited composite material is substantially free from voids.
[0130] Within this application, core reinforced filaments are
described as being either impregnated or wetted. For example, a
solid core might be let with a matrix material, or a multifilament
core may be both impregnated and fully wet with a matrix material.
However, for the purposes of this application, a filament including
a core that has been impregnated should be understood to refer to a
filament including a core that has been fully impregnated and/or
wet with matrix material. A person of ordinary skill would be able
to understand how this might be interpreted for applications where
a core material is a solid core.
[0131] In addition to the above, a core reinforced material as
described throughout this application. For specific embodiments and
examples, a continuous core and/or a semi-continuous core might be
described for exemplary purposes. However, it should be understood
that either a continuous and/or a semi-continuous core might be
used in any particular application and the disclosure is not
limited in this fashion. Additionally, with regards to a core
reinforced material, the core may either be positioned within an
interior of the filament or the core material may extend to an
exterior surface of the filament as the disclosure is not limited
in this fashion. Additionally, it should be understood that a court
reinforced material also includes reinforcements provided by
materials such as optical materials, fluid conducting materials,
electrically conductive materials as well as any other appropriate
material as the disclosure is not so limited.
[0132] In yet another embodiment, the inventors have recognized the
benefits associated with providing a continuous or semi-continuous
core combined with stereolithography (SLA), selective laser
sintering (SLS), and other three dimensional printing processes
using a matrix in liquid or powder form to form a substantially
void free parts exhibiting enhanced strength. The above embodiments
may help to reduce, or eliminate, the need for a subsequent vacuum
step as well as improve the strength of the resulting printed
structures by helping to reduce or eliminate the presence of voids
within the final structure.
[0133] In addition to improvements in strength due to the
elimination of voids, the inventors have recognized that the
current limitation of laying down a single strip at a time in three
dimensional printing processes may be used as an advantage in
composite structure manufacturing. For example, the direction of
reinforcing materials deposited during the printing process within
a structure may be controlled within specific layers and portions
of layers to control the directional strength of the composite
structure both locally and overall. Consequently, the
directionality of reinforcement within a structure can provide
enhanced part strength in desired locations and directions to meet
specific design requirements. The ability to easily tailor the
directional strength of the structure in specific locations may
enable both lighter and stronger resulting parts.
[0134] In embodiments, it may be desirable to include a cutting
mechanism with the three dimensional printing system. Such a
cutting mechanism may be used to provide selective termination in
order to deposit a desired length of material. Otherwise, the
printing process could not be easily terminated due to the
deposited material still being connected to the material within the
extrusion nozzle b, for example, a continuous core. The cutting
mechanism may be located at the outlet of the associated printer
nozzle or may be located upstream from the outlet. Further, in some
embodiments, the cutting mechanism is located between a feeding
mechanism for the core material and the outlet of the nozzle.
However regardless of the specific configuration and location, the
cutting mechanism enables the three dimensional printing system to
quickly and easily deposit a desired length of material in a
desired direction at a particular location. In contrast, systems
which do not include a cutting mechanism continuously deposit
material until the material runs out or it is manually cut. This
limits both the complexity of the parts that can be produced, the
speed of the printing process as well as the ability to deposit the
material including the continuous core in a particular direction.
Depending on the embodiment, the cutting mechanism may also
interrupt the printer feed by blocking the nozzle or preventing the
feeding mechanism from applying force or pressure to a portion of
the material downstream from the cutting mechanism. While in some
cases it may be desirable to include a cutting mechanism with the
three dimensional printer, it should be understood that embodiments
described herein may be used both with and without a cutting
mechanism as the current disclosure is not limited in this fashion.
Further, a cutting mechanism may also be used with embodiments that
do not include a continuous core.
[0135] It should be understood that the substantially void free
material described herein may be manufactured in any number of
ways. However, in one embodiment, the material is formed by
applying a varying pressure and/or forces in different directions
during formation of the material. For example, in one embodiment,
multiple strands of a polymer or resin and a core including a
plurality of reinforcing fibers are co-mingled prior to feeding
into a system. The system then heats the materials to a desired
viscosity of the polymer resin and applies varying pressures and/or
forces in alternating directions to the comingled towpreg to help
facilitate fully impregnating the fibers of the towpreg with the
polymer or resin. This may be accomplished using a smooth
circuitous path including multiple bends through which a green
towpreg is passed, or it may correspond to multiple offset rollers
that change a direction of the towpreg as it is passed through the
system. As the towpreg passes through this circuitous path, the
varying forces and pressures help to fully impregnate the polymer
into the core and form a substantially void free material. While a
co-mingled towpreg including separate strands of reinforcing fibers
and polymer resin are described above, embodiments in which a solid
core and/or multiple reinforcing fibers are comingled with polymer
particles, or dipped into a liquid polymer or resin, and then
subjected to the above noted process are also contemplated. In
addition to the above, after impregnating the core with the
polymer, the substantially void free material may be fed through a
shaping nozzle to provide a desired shape. The nozzle may be any
appropriate shape including a circle, an oval, a square, or any
other desired shape. While a continuous core is noted above,
embodiments in which a semi-continuous core is used are also
contemplated. Additionally, this formation process may either be
performed under ambient conditions, or under a vacuum to further
eliminate the presence of voids within the substantially void free
material.
[0136] In some embodiments, it may be desirable to provide a smooth
outer coating on a towpreg corresponding to the substantially void
free material noted above. In such an embodiment, a substantially
void free material, which is formed as noted above, or in any other
appropriate process, is co-extruded with a polymer through an
appropriately shaped nozzle. As the substantially void free
material and polymer are extruded through the nozzle, the polymer
forms a smooth outer coating around the substantially void free
material.
[0137] The materials used with the currently described three
dimensional printing processes may incorporate any appropriate
combination of materials. For example appropriate resins and
polymers include, but are not limited to, acrylonitrile butadiene
styrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI), Polyether
ether ketone (PEEK), Polyactic Acid (PLA), Liquid Crystal Polymer,
and various other thermoplastics. The core may also be selected to
provide any desired property. Appropriate core filaments include
those materials which impart a desired property, such as
structural, conductive (electrically and/or thermally), insulative
(electrically and/or thermally), optical and/or fluidic transport.
Such materials include, but are not limited to, carbon fibers,
aramid fibers, fiberglass, metals (such as copper, silver, gold,
tin, steel), optical fibers, and flexible tubes. It should be
understood that the core filaments may be provided in any
appropriate size. Further, multiple types of continuous cores may
be used in a single continuous core reinforced filament to provide
multiple functionalities such as both electrical and optical
properties. It should also be understood that a single material may
be used to provide multiple properties for the core reinforced
filament. For example, a steel core might be used to provide both
structural properties as well as electrical conductivity
properties.
[0138] In some embodiments, in addition to selecting the materials
of the core reinforced filament, it is desirable to provide the
ability to use core reinforced filaments with different resin to
reinforcing core ratios to provide different properties within
different sections of the part. For example, a low-resin filler may
be used for the internal construction of a part, to maximize the
strength-to-weight ratio (20% resin by cross sectional area, for
example). However, on the outer cosmetic surface of the part, a
higher, 90% resin consumable may be used to prevent the possible
print through of an underlying core or individual fiber strand of
the core. Additionally, in some embodiments, the consumable
material may have zero fiber content, and be exclusively resin.
Therefore, it should be understood that any appropriate percentage
of resin may be used.
[0139] The core reinforced filaments may also be provided in a
variety of sizes. For example, a continuous or semi-continuous core
reinforced filament may have an outer diameter that is greater than
or equal to about 0.001 inches and less than or equal to about 0.4
inches. In one specific embodiment, the filament is greater than or
equal to about 0.010 inches and less than or equal to about 0.030
inches. In some embodiments, it is also desirable that the core
reinforced filament includes a substantially constant outer
diameter along its length. Depending on the particular embodiment,
different smoothnesses and tolerances with regards to the core
reinforced filament outer diameter may be used. Without wishing to
be bound by theory, a constant outer diameter may help to provide
constant material flow rate and uniform properties in the final
part.
[0140] As described in more detail below, the ability to
selectively print electrically conductive, optically conductive,
and/or fluidly conductive cores within a structure enables the
construction of desired components in the structure. For example,
electrically conductive and optically conductive continuous cores
may be used to construct strain gauges, optical sensors, traces,
antennas, wiring, and other appropriate components. Fluid
conducting cores might also be used for forming components such as
fluid channels and heat exchangers. The ability to form functional
components on, or in, a structure offers multiple benefits. For
example, the described three dimensional printing processes and
apparatuses may be used to manufacture printed circuit boards
integrally formed in a structure, integrally formed wiring and
sensors in a car chassis or plane fuselage: as well as motor cores
with integrally formed windings to name a few.
[0141] Turning now to the figures, specific embodiments of the
disclosed materials and three dimensional printing processes are
described.
[0142] FIG. 1 depicts an embodiment of a three dimensional printer
using continuous strands of composite material to build a
structure. In the depicted embodiment, the continuous strand of
composite material is a continuous core reinforced filament 2. The
continuous core reinforced filament 2 is a towpreg that is
substantially void free and includes a polymer 4 that coats or
impregnates an internal continuous core 6. Depending upon the
particular embodiment, the core 6 may be a solid core or it may be
a multifilament core including multiple strands.
[0143] The continuous core reinforced filament 2 is fed through a
heated nozzle, such as extrusion nozzle 10. As the continuous core
reinforced filament is fed through the extrusion nozzle it is
heated to a preselected extrusion temperature. This temperature may
be selected to effect any number of resulting properties including,
but not limited to, viscosity of the extruded material, bonding of
the extruded material to the underlying layers, and the resulting
surface finish. While the extrusion temperature may be any
appropriate temperature, in one embodiment, the extrusion
temperature is greater than the melting temperature of the polymer
4, but is less than the decomposition temperature of the resin and
the melting or decomposition temperature of the core 6. Any
suitable heater may be employed to heat the nozzle, such as a band
heater or coil heater.
[0144] After being heated in the heated extrusion nozzle 10, the
continuous core reinforced filament 2 is extruded onto a build
platen 16 to build successive layers 14 to form a final three
dimensional structure. The position of the heated extrusion nozzle
10 relative to the build platen 16 during the deposition process
may be controlled in any appropriate fashion. For example, the
position and orientation of the build platen 16 or the position and
orientation of the heated extrusion nozzle 10 may be controlled by
a controller 20 to deposit the continuous core reinforced filament
2 in the desired location and direction as the current disclosure
is not limited to any particular control method. Also, any
appropriate movement mechanism may be used to control either the
nozzle or the build platen including gantry systems, robotic arms,
H frames, and other appropriate movement systems. The system may
also include any appropriate position and displacement sensors to
monitor the position and movement of the heated extrusion nozzle
relative to the build platen and/or a part being constructed. These
sensors may then communicate the sensed position and movement
information to the controller 20. The controller 20 may use the
sensed X, Y, and/or Z positions and movement information to control
subsequent movements of the heated extrusion head or platen. For
example, the system might include rangefinders, displacement
transducers, distance integrators, accelerometers, and/or any other
sensing systems capable of detecting a position or movement of the
heated extrusion nozzle relative to the build platen. In one
particular embodiment, and as depicted in the figure, a laser range
finder 15, or other appropriate sensor, is used to scan the section
ahead of the heated extrusion nozzle in order to correct the Z
height of the nozzle, or fill volume required, to match a desired
deposition profile. This measurement may also be used to fill in
voids detected in the part. Additionally, the range finder 15, or
another range finder could be used to measure the part after the
material is extruded to confirm the depth and position of the
deposited material.
[0145] Depending on the embodiment, the three dimensional printer
includes a cutting mechanism 8. The cutting mechanism 8
advantageously permits the continuous core reinforced filament to
be automatically cut during the printing process without the need
for manual cutting or the formation of tails as described in more
detail below. By cutting the continuous core reinforced filament
during the deposition process, it is possible to form separate
features and components on the structure as well as control the
directionality of the deposited material in multiple sections and
layers which results in multiple benefits as described in more
detail below. In the depicted embodiment, the cutting mechanism 8
is a cutting blade associated with a backing plate 12 located at
the nozzle outlet, though other locations are possible. While one
embodiment of the cutting mechanism including a cutting blade is
shown, other types of cutting mechanisms as described in more
detail below are also possible, including, but not limited to,
lasers, high-pressure air, high-pressure fluid, shearing
mechanisms, or any other appropriate cutting mechanism. Further,
the specific cutting mechanism may be appropriately selected for
the specific feed material used in the three dimensional
printer.
[0146] FIG. 1 also depicts a plurality of optional secondary print
heads 18 that are employed with the three dimensional printer in
some embodiments. A secondary print head 18 may be used to deposit
inks, or other appropriate optional coatings, on the surface of a
three dimensional printed part. In one embodiment, the secondary
print head is similar to an existing inkjet printer. Such a print
head may be used to print photo-quality pictures and images on the
part during the manufacturing process. The print head might use UV
resistant resins for such a printing process. Alternatively, the
print head may be used to print protective coatings on the part.
For example, the print head might be used to provide a UV resistant
or a scratch resistant coating.
[0147] FIG. 2 presents a schematic flow diagram of a three
dimensional printing process using the system and controller
depicted in FIG. 1. Initially a continuous core reinforced filament
is provided at 102. The continuous core reinforced filament is then
fed into the heated extrusion nozzle and heated to a desired
temperature that is greater than a melting temperature of the resin
and is less than a melting temperature of the continuous core at
104 and 106. The three dimensional printer then senses a position
and movement of the heated extrusion nozzle relative to the build
platen or part at 108. After determining the position and movement
of the heated extrusion nozzle, the nozzle is moved to a desired
location and the continuous core reinforced filament is extruded at
the desired location and along a desired path and direction at 110.
Embodiments are also envisioned in which the build platen or part
are moved relative to the nozzle. After reaching the desired
termination point, the continuous core reinforced filament is cut
at 112. The controller may then determine if the three dimensional
part is completed. If the printing process is not completed the
controller may return to 108 during which it senses the current
position and movement of the nozzle prior to depositing the next
piece of continuous core reinforced filament. If the part is
completed, the final part may be removed from the build platen.
Alternatively, an optional coating may be deposited on the part
using a secondary print head at 116 to provide a protective coating
and/or apply a figure or image to the final part. It should be
understood that the above noted steps may be performed in a
different order than presented above. Further, in some embodiments,
additional steps may be used and/or omitted as the current
disclosure is not limited to only the processes depicted in FIG.
2.
[0148] FIGS. 3A-3E depict various embodiments of core
configurations of a continuous core reinforced filaments 2. In
addition to the specific core configurations, the materials are
processed to be substantially void-free which helps with both the
binding of the individual layers and resulting strength of the
final structures.
[0149] FIGS. 3A and 3B depict the cross-section of a continuous
core reinforced filament including a solid core 6a encased in a
surrounding polymer 4 or resin. There are substantially no voids
present either in the polymer or between the polymer and solid
core. FIG. 3A depicts a continuous core reinforced filament that
includes a cross section with a larger proportion of polymer. FIG.
3B depicts a cross section with a larger solid core and
correspondingly larger proportion of reinforcing core material. It
should be understood that any appropriate proportion of continuous
core area to polymer area may be used. Further, without wishing to
be bound by theory, materials with a larger proportion of polymer
may result in smoother surface finishes and better adhesion between
the layers. Conversely, larger proportions of the continuous core
filament may be used to increase the strength to weight ratio of
the final constructed component since the fiber material
constitutes the bulk of the strength of the composite and is
present in a larger proportion. A larger core may also be
advantageous when the core is made from copper or another
appropriate electrically or optically conductive material, since it
may be desirable to have a large core to increase the conductivity
of the deposited material.
[0150] FIGS. 3C and 3D depict yet another embodiment in which the
core material of the continuous core reinforced filament 2 is a
continuous multifilament core material 6b surrounded by and
impregnated with a polymer 4 which is wicked into the cross section
of the multifilament core. FIG. 3C depicts a smaller proportion of
multifilament core material 6b surrounded by and impregnated with
the polymer 4. FIG. 3D illustrates an embodiment with a very small
amount of resin and a large proportion of multifilament core
material 6b such that the multifilament core material fills
virtually the entire cross section. In such an embodiment, the
polymer 4 acts more as a binder impregnated into the multifilament
core material 6b to hold it together. Similar to the above noted
solid cores, any appropriate proportion of resin to multifilament
core material may be used to provide a selected strength, surface
finish, conductivity, adhesion, or other desired property to the
resulting continuous core reinforced filament 2.
[0151] FIG. 3E, depicts a variation of the continuous multifilament
core. In this embodiment, the continuous core reinforced filament 2
still includes a continuous multifilament core material 6b
surrounded by and impregnated with a polymer 4. However, the core
also includes one or more secondary strands of core materials 6c
and 6d. These secondary core materials might be optically
conducting, electrically conducting, thermally conducting, fluid
conducting, or some combination of the above. These secondary core
materials could be used to conduct power, signals, heat, and fluids
as well as for structural health monitoring and other desired
functionalities.
[0152] In order to avoid the entrapment of voids within the core
reinforced filament 2 described above, the polymer material is
processed such that the molten polymer or polymer resin wicks into
the reinforcing fibers during the initial production of the
material. In some embodiments, the polymer is substantially wicked
into the entire cross-section of a multifilament core which helps
to provide a substantially void free material. To produce the
desired core reinforced filaments, the core reinforced filament may
be pre-treated with one or more coatings to activate the surface,
and subsequently exposed to one or more environmental conditions
such as temperature, pressure, and/or chemical agents such as
plasticizers, to aid the polymer or resin wicking into the cross
section of the multifilament core without the formation of any
voids. In some embodiments, this process may be performed prior to
entering a feed head of the three dimensional printer. However, in
other embodiments, the core reinforced filament is formed on a
completely separate machine prior to the printing process and is
provided as a consumable printing material. Since the subsequent
deposition process does not need to be run at temperatures high
enough to wet the core materials with the polymer or resin, the
deposition process can be run at lower temperatures and pressures
than required in typical systems. While the above process may be
applied to both the solid and multifilament cores, it is more
beneficial to apply this process to the multifilament cores due to
the difficulty associated with wicking into the multifilament core
without forming voids. Further, by forming the core reinforced
filament either separately or prior to introduction to the nozzle,
the material width and proportions may be tightly controlled
resulting in a more constant feed rate of material when it is fed
into a three dimensional printer.
[0153] In contrast to the above materials formed substantially
without voids, the prior art has employed "green" deposition
processes including reinforcing filaments that have been dipped
into a resin or molten polymer and wicked with the multifilament
cores during the extrusion process itself might also be use. In
order to do this, the resin or polymer is heated substantially past
the melting point, such that the viscosity is sufficiently low to
allow the resin or polymer to wick into the reinforcing fibers.
This process may be aided by a set of rollers which apply pressure
to the materials to aid in wicking into the reinforcing fibers.
However, due to the arrangement of the rollers and the temperature
of the temperature of the towpreg as it exits the rollers, this
process typically results in voids being entrapped in the material
prior to final formation. After the resin or polymer has wicked
into the reinforcing fibers, the resulting "towpreg" or "tow" is
typically cooled to just above the melting point prior to
extrusion. However, this process is typically done in air which
combined with the air present in the material when it is inserted
into the nozzle results in ambient air being entrapped in the
material as described in more detail below.
[0154] Such a wicking process during the extrusion of a typical
towpreg is depicted in FIG. 4. As depicted in the figure, prior to
the wicking and extrusion process, a green towpreg 22 includes
multiple green matrix resin particles or filaments 24 mixed with
multiple reinforcing fibers 28 as well as a surrounding amount of
air 24. As depicted in the figure, the reinforcing fibers 28 are
distributed randomly across the cross section. As the towpreg 22
passes through heating zone 30 of the extrusion nozzle, the
material is heated to induce fiber wetting and form a cured resin
32. The surrounding air 26 also becomes entrapped in the towpreg
forming air voids 34. These entrapped air voids 34 then become
embedded in the resultant printed part. Additionally, the air voids
34 may result in non-bonded sections 36 of the fibers. Since these
non-bonded sections of the reinforcing fibers are not in contact
with the polymer, the resulting composite material will be weaker
in this location. In contrast, the continuous core reinforced
filament in the illustrative embodiment depicted in FIGS. 3A-3E are
substantially free from voids and in at least some embodiments the
cores are centrally located within the surrounding resin. Without
wishing to be bound by theory, this results in a stronger more
uniform material and resultant part.
[0155] While the currently described three dimensional printer
systems are primarily directed to using the preimpregnated or
wetted core reinforced filaments described herein, in some
embodiments the three dimensional printer system might use a
material similar to the green comingled towpreg 22 depicted in FIG.
4. However, as noted above, it is desirable to avoid the formation
of entrapped air voids during curing of the material within the
nozzle. One possible way to avoid the formation of air voids in the
deposited material, is to provide a vacuum within the nozzle. By
providing a vacuum within the nozzle, there is no air to entrap
within the towpreg when it is heated and cured within the nozzle.
Therefore, in some embodiments, the nozzle is configured to allow
the introduction of a continuous green material including a solid
or multifilament core while under vacuum. The continuous green
material may then be heated to an appropriate temperature above the
melting temperature of a resin or polymer within the continuous
green material while under vacuum to facilitate wicking of the
resin or polymer into the core to produce a substantially void free
material. Another method is the use of a circuitous path, which may
be provided by offset rollers or other configurations as described
below, to mechanically work out the entrapped air. Optionally, a
vacuum may also be applied in conjunction with the mechanical
removal of air bubbles through the circuitous path.
[0156] In addition to the material used for printing the three
dimensional part, the specific nozzle used for depositing the core
reinforced filament also has an effect on the properties of the
final part. For example, the extrusion nozzle geometry used in
typical three dimensional printers is a convergent nozzle, see FIG.
5. Convergent nozzles used in typical three dimensional printers
typically have feed stock that is about 0.060 inches to 0.120
inches (1.5 mm-3 mm) in diameter. This stock is squeezed through a
nozzle that typically necks down to about a 0.008 inch to 0.016
inch (0.2 mm-0.4 mm) tip orifice. However, such a nozzle may not be
desirable for use with feed stock including a continuous core for
the reasons described below.
[0157] Without wishing to be bound by theory, as the stock material
is fed into the converging nozzle, the constraining geometry causes
the fluid polymer matrix material to accelerate relative to the
continuous core. Additionally, the matrix and core generally have
different coefficients of thermal expansion. Since the matrix
material is a polymer it generally has a larger coefficient of
thermal expansion. Therefore, as the matrix material is heated it
also accelerates relative to the fiber due to the larger expansion
of the matrix material within the confined space of the converging
nozzle. The noted acceleration of the matrix material relative to
the fiber results in the matrix material flow rate v.sub.matrix
being less than the fiber material flow rate v.sub.fiber near the
nozzle inlet. However, the matrix material flow rate at the outlet
v.sub.matrix is equal to the fiber material flow rate v.sub.fiber.
As illustrated in the figure, these mismatched velocities of the
matrix material and fiber within the converging nozzle may result
in the fiber collecting within the nozzle during the deposition
process. This may lead to clogging as well as difficulty in
controlling the uniformity of the deposition process. It should be
understood that while difficulties associated with a converging
nozzle have been noted above, a converging nozzle may be used with
the embodiments described herein as the current disclosure is not
limited in this fashion.
[0158] In view of the above, it is desirable to provide a nozzle
geometry that is capable of maintaining a matched velocity of the
individual strands of multifilament core material 6b, or other
appropriate core, and the polymer 4 or other matrix material
throughout the nozzle for a given matrix and core combination. For
example, FIG. 6A depicts a divergent nozzle 200 with an increasing
nozzle diameter that matches the thermal expansion of the matrix
material. As depicted in the figure, the nozzle 200 includes an
inlet 202 with a diameter D1, a section with an increasing diameter
204, and an outlet 206 with a diameter D2 that is greater than the
diameter D1. Without wishing to be bound by theory, by matching the
nozzle diameter to the expected expansion of the matrix material
within the nozzle, the matrix and the continuous core reinforcing
are kept at substantially the same velocity relative to one another
throughout the entire nozzle. Therefore, the linear extrusion rate
of the matrix material and the continuous core is the same and the
continuous core does not build up within the nozzle.
[0159] In addition to the above, in some embodiments, the matrix
material and the continuous core have relatively low coefficients
of thermal expansion (such as carbon fiber and Liquid Crystal
Polymer). In such an embodiment, since the matrix material and
reinforcing fibers stay substantially the same size, the nozzle 200
may include an inlet 202 and outlet 206 that have substantially the
same diameter D3, see FIG. 6B. Therefore, while some nozzle designs
may have divergent geometries, in some embodiments the nozzle
geometry may be substantially linear and may have substantially
similar inlet and extrusion areas.
[0160] In addition to controlling the relative sizing of the nozzle
inlet and outlet, a nozzle 200 may also include a rounded nozzle
outlet 208, see FIG. 6C. The rounded nozzle outlet 208 may have any
appropriate form and size. For example, the rounded nozzle outlet
208 may be embodied by an outwardly extending lip, a chamfer, a
filet, an arc, or any other appropriate geometry providing a smooth
transition from the nozzle outlet. Without wishing to be bound by
theory, a rounded nozzle outlet providing a smooth transition from
the nozzle internal bore may help to avoid applying excessive
stresses to, and/or scraping, the continuous material as it is
extruded from the nozzle 200. This smooth transition provided by
the rounded nozzle outlet may help to avoid fracturing the
continuous core filament during deposition.
[0161] FIG. 7 illustrates a potential disadvantage with printing a
continuous core reinforced filament without an integrated cutter in
the print head. As depicted in the figure, print head 300 is
forming part 302, and is shown having deposited the last section of
material layer 304. Since typical Fused Filament Fabrication (FFF),
also known as Fused Deposition Modeling (FDM), techniques place the
print head close to the underlying part, and often touching the top
of the extruded plastic, there is little to no room in which to
introduce an external cutting mechanism. Indeed, without a near
zero-thickness blade, the print head needs to print a tag-end
over-run 306 not specified in the part in order to enable a
separate cutting mechanism, or person, to cut the continues core
and terminate the printing process. However, this leaves
undesirable tag-end over-runs 306 at each fiber termination point.
As shown in FIG. 7, a plurality of internal features, such as hard
mounting bosses 308 would all have a tag-end over-run 306 at each
layer within the boss. In view of the above, an integrated cutting
mechanism may enable less post-processing, and would allow the
machine to simply print the intended part with smaller and fewer
tag-end over-runs. Further, in some embodiments, and as described
in more detail below, the cutting mechanism may eliminate the
presence of tag-end over-runs altogether.
[0162] FIG. 8 depicts two embodiments of a cutting mechanism for
use with a three dimensional printer. As depicted in the figure, an
appropriate feed material, which in this example is a continuous
core reinforced filament 2a, though other suitable filaments may be
used, is removed from a spool 38 and passed through a feeding
mechanism such as driving roller 40 and idle wheel 42. The driving
roller 40, or any other appropriate feeding mechanism, is
constructed and arranged to apply a force directed in a downstream
direction to, in this example, the continuous core reinforced
filament 2a. Therefore, the continuous core reinforced filament 2a
may be at a temperature such that it is in a solid or semi solid
state when this force is applied. For example, the force may be
applied to the material when it is at room temperature, below a
glass transition temperature of the material, between room
temperature in the glass transition temperature, or any other
appropriate temperature at which the material is capable of
supporting the applied force. The applied downstream force results
in the continuous core reinforced filament 2a entering and being
extruded from a heated nozzle 10 to build up a three dimensional
part. While a driving roller has been depicted, it should be
understood, that any appropriate feeding mechanism might be
used.
[0163] In the first embodiment, a cutting mechanism 8a, such as a
blade, is positioned at the outlet of the heated extrusion nozzle
10. Such a configuration allows actuation of the cutting mechanism
to completely cut the deposited strip by severing the internal
continuous core. Additionally, in some embodiments, the nozzle
pressure is maintained during the cutting process, and the cutting
blade is actuated to both cut the internal strand, and to prevent
further extrusion of the continuous fiber reinforced material and
dripping by physically blocking the nozzle outlet. Thus, the
cutting mechanism enables the deposition of continuous core
reinforced filament, as well as unreinforced materials, with
precisely selected lengths as compared to traditional three
dimensional printers.
[0164] In the second depicted embodiment shown integrated with the
same system, a cutting mechanism 8b is located upstream from the
nozzle outlet. More specifically, the cutting mechanism 8b may be
located within the hot end of the nozzle, or further upstream
before the continuous core reinforced filament has been heated. In
some embodiments, the cutting mechanism 8b is located between the
nozzle outlet and the feeding mechanism 40. Such an embodiment may
permit the use of a smaller gap between the nozzle outlet and the
part since the cutting mechanism does not need to be accommodated
in the space between the nozzle outlet and the part. Depending on
the particular location, the cutting mechanism 8b may cut the
continuous core filament and the surrounding matrix while the
temperature is below the melting or softening temperature and in
some embodiments below the glass transition temperature. Without
wishing to be bound by theory, cutting the continuous core
reinforced filament while it is below the melting, softening,
and/or glass transition temperatures of the polymer may reduce the
propensity of the resin to stick to the blade which may reduce
machine jamming. Further, cutting when the resin or polymer is
below the melting point may help to enable more precise metering of
the deposited material. The position of a cut along the continuous
core reinforced filament may be selected to eliminate the presence
of tag-end over-runs in the final part which may facilitate the
formation of multiple individual features.
[0165] As shown in the figure, the downstream portion 2b of the
continuous core reinforced filament can be severed from the
upstream portion 2a of the continuous core reinforced filament by
the upstream cutting mechanism 8b. By maintaining a close fit
between the feed material, and the guiding tube within which it
resides, the downstream portion 2b of the cut strand can still be
pushed through the machine by the upstream portion 2a which is
driven by the drive roller 40 or any other appropriate feeding
mechanism. Without wishing to be bound by theory, the previously
deposited and cooled material is also adhered to the previously
deposited layer and will drag the continuous core reinforced
filament 2b out of the heated extrusion nozzle 10 when the print
head is moved relative to the part which will apply a force to the
continuous core located in the downstream portion of the cut
strand. Therefore, a combination of upstream forces from the
feeding mechanism and downstream forces transferred through the
continuous core may be used to deposit the cut section of material.
Again, the position of a cut along the continuous core reinforced
filament may be selected to eliminate the presence of tag-end
over-runs in the final part.
[0166] While embodiments including an integrated cutting mechanism
have been depicted above, embodiments not including a cutting
mechanism are also possible as the current disclosure is not
limited in this fashion. For example embodiments in which a part is
printed in a contiguous string fashion, such that termination of
the continuous material is not required might be used. In once such
embodiment, the three dimensional printing machine might not be
able to achieve fiber termination, and would therefore print a
length of material until the part was complete, the material ran
out, or a user cuts the deposited material.
[0167] While cutting of the continuous fiber reinforced material
helps to eliminate the presence of tag-end over-runs, it is also
desirable to prevent buckling of the material to help ensure a
uniform deposition and prevent machine jams. Without wishing to be
bound by theory, the stiffness of a material is proportional to the
diameter of the material squared. Therefore, continuous materials
with large diameters do not need as much support to be fed into an
inlet of the nozzle as depicted in the figure. However, as the
diameter of the continuous material decreases, additional features
may be necessary to ensure that buckling of the continuous material
and any continuous core filament contained within it does not
buckle. For example, a close-fitting guide tube as described in
more detail below, may be used in combination with positioning the
feeding mechanism closer to the inlet of the nozzle or guide tube
to help prevent buckling of the material. Therefore, in one
embodiment, the feeding mechanism may be located within less than
about 20 diameters, 10 diameters, 8 diameters, 6 diameters, 5
diameters, 4 diameters, 3 diameters, 2 diameters, 1 diameter, or
any other appropriate distance from a guide tube or inlet to the
nozzle.
[0168] In addition to preventing buckling, in some embodiments, the
maximum tension or dragging force applied to the deposited
reinforcing fibers is limited to prevent the printed part from
being pulled up from a corresponding build plane or to provide a
desired amount of tensioning of the continuous core. The force
limiting may be provided in any number of ways. For example, a
one-way locking bearing might be used to limit the dragging force.
In such an embodiment, the drive motor may rotate a drive wheel
though a one-way locking bearing such that rotating the motor
drives the wheel and extrudes material. If the material dragging
exceeds the driven speed of the drive wheel, the one-way bearing
may slip, allowing additional material to be pulled through the
feeding mechanism and nozzle, effectively increasing the feed rate
to match the head traveling speed while also limiting the driving
force such that it is less than or equal to a preselected limit.
The dragging force may also be limited using a clutch with
commensurate built-in slip. Alternatively, in another embodiment,
the normal force and friction coefficients of the drive and idler
wheels may be selected to permit the continuous material to be
pulled through the feeding mechanism above a certain dragging
force. Other methods of limiting the force are also possible. In
yet another environment, an AC induction motor, or a DC motor
switched to the "off" position (e.g. depending on the embodiment
this may correspond to either a small resistance being applied to
the motor terminals or opening a motor terminals) may be used to
permit the filament to be pulled from the printer. In such an
embodiment, the motors may be allowed to freewheel when a dragging
force above a desired force threshold is applied to allow the
filament to be pulled out of the printer. In view of the above, a
feeding mechanism is configured in some form or fashion such that a
filament may be pulled out of the printer nozzle when a dragging
force applied to the filament is greater than a desired force
threshold. Additionally, in some embodiments, a feeding mechanism
may incorporate a sensor and controller loop to provide feedback
control of either a deposition speed, printer head speed, and/or
other appropriate control parameters based on the tensioning of the
filament.
[0169] A printer system constructed to permit a filament to be
pulled out of a printer nozzle as described above, may be used in a
number of ways. However, in one embodiment, the printing system
drags a filament out of a printer nozzle along straight printed
sections. During such operation a printer head may be displaced at
a desired rate and the deposited material which is adhered to a
previous layer or printing surface will apply a dragging force to
the filament within the printing nozzle. Consequently, the filament
will be pulled out of the printing system and deposited onto the
part. When printing along curves and/or corners, the printing
system extrudes and/or pushes the deposited filament onto a part or
surface. Of course embodiments in which a filament is not dragged
out of the printing system during operation and/or where a filament
is dragged out of a printer head when printing a curve and/or
corner are also contemplated.
[0170] The currently described three dimensional printing methods
using continuous core reinforced filaments also enable the bridging
of large air gaps that previously were not able to be spanned by
three dimensional printers. Without wishing to be bound by theory,
the deposition of tensioned continuous core reinforced filaments
including a non-molten, i.e. solid, continuous core enables the
deposited material to be held by the print head on one end and
adhesion to the printed part on the other end. The print head can
then traverse an open gap, without the material sagging. Thus, the
printer can print in free space which enables the printer to jump a
gap, essentially printing a bridge between two points. This enables
the construction of hollow-core components without the use of
soluble support material.
[0171] FIG. 8 depicts free-space printing enabled by the continuous
core reinforced filament. With the continuous core reinforced
filament 2b attached to the part at point 44, and held by the print
head at point 46, it is possible to bridge the gap 48. In typical
FFF printers, the extruded material will sag, and fall into the gap
48 because it is molten and unsupported. However, having a
continuous core of non-molten material supporting the molten
polymer enables printing in free-space, advantageously enabling
many new types of printing. For example, a closed section box shown
in FIG. 9 is formed by a section 50 which is bridges gap 48 and is
affixed to opposing sections 52 and 54. While this example shows a
closed section bridge, the free-space printing could also be used
to produce cantilevers, and unsupported beams, that cannot be
printed with typical unsupported materials.
[0172] In some embodiments, a cooling mechanism such as a jet of
cooling air may be applied to the extruded material to further
prevent sagging by solidifying the polymer material surrounding the
core. The extruded material may either be continuously cooled while
building a component with sections over gaps. Alternatively, in
some embodiments, the extruded material might only be cooled while
it is being extruded over a gap. Without wishing to be bound by
theory, selectively cooling material only while it is over a gap
may lead to better adhesion with previously deposited layers of
material since the deposited material is at an elevated temperature
for a longer period which enhances diffusion and bonding between
the adjacent layers.
[0173] In the above noted embodiments, a cutting blade is located
upstream of the nozzle to selectively sever a continuous core when
required by a printer. While that method is effective, there is a
chance that a towpreg will not "jump the gap" correctly between the
cutting mechanism and the nozzle. Consequently, in at least some
embodiments, it is desirable to increase the reliability of
rethreading the core material after the cutting step.
[0174] As described in more detail below, in some embodiments, a
cutting mechanism is designed to reduce or eliminate the
unsupported gap after the cutting operation. In such an embodiment,
a tube-shaped shear cutter may be used. As described in more detail
below, a towpreg is contained within two intersecting tubes that
shear relative to each other to cut the towpreg. In such an
embodiment, a gap sufficient to accommodate movement of the two
tilted to each other. The tubes are subsequently moved back into
alignment to resume feeding the material. In this mechanism there
is effectively no gap to jump after the cutting operation since the
tubes are realigned after cutting. In some embodiments, the gap
required for the cutting operation is reduced or eliminated by
moving the guide tubes axially together after the cut, thus,
eliminating the gap and preventing the fiber from having to jump
the gap. In other embodiments, and as described in more detail
below, the cutting mechanism may be integrated into a tip of a
printer head nozzle to eliminate the need for a gap.
[0175] FIG. 10 depicts a compression-based continuous-core print
head. As depicted in the figures, the input material is a towpreg
such as a continuous core filament 2 which is drawn into the feed
rollers 40 and 42 under tension. To facilitate guiding and
maintaining alignment of the continuous core filament 2 with the
rollers 40 and 42, in some embodiments, the continuous core
filament 2 passes through a guide tube 74 positioned upstream of
the rollers. After passing through the rollers, the continuous core
filament 2 is placed in compression. As noted above, depending on a
length of the material under compression as well as a magnitude of
the applied force, the continuous core filament 2 may buckle.
Consequently, in some embodiments, the continuous core filament 2
passes through a close-fitting guide tube 72 positioned downstream
of the rollers and upstream of the nozzle. The guide tube 72 will
both guide and substantially prevent buckling of the continuous
core filament 2. Similar to the above embodiments, a cutting
mechanism 8 corresponding to a blade is positioned downstream of
the guide tube 72. The gap 62 present between the printer head 70
and the cutting mechanism 8 is illustrated in the figure. When the
continuous core filament 2 is cut by the cutting mechanism 8, the
material is "rethreaded" by passing from one side of the gap 62 to
the other side and into receiving tube 64. In some embodiments, the
receiving tube 64 is advantageously below the glass transition
temperature of the material, such that the entirety of the cutting
operation occurs within solid material. In the depicted embodiment,
a thermal spacer 66 is located between the receiving tube 64 and
the hot melt nozzle 68. The thermal spacer 66 reduces the heat
transfer to the receiving tube 64 from the hot melting nozzle 68.
Similar to the previous embodiment, the continuous-core material 2
is deposited, layer-by-layer 14 onto a build plate 16. FIG. 11 is a
photograph of a system including the above-noted components.
[0176] In some embodiments, the filament used with the device
depicted in FIG. 10 is provided on a spool 76. When provided in
this form, the material is preformed, substantially solid, and
substantially rigid. For example, a preimpregnated core reinforced
filament might be provided. Since the material has already been
formed, it is less likely to stick to the various components and/or
delaminate during use as might be the case for a green towpreg
which may or may not include an uncured resin. By providing the
filament in a preformed state, the filament is able to support
compressive forces in addition to being easier to manipulate. This
facilitates both handling during threading of the system as well as
applying compressive forces to the material during deposition using
a compression-based printer head as described herein.
[0177] Without wishing to be bound by theory, the difficulty in
jumping the gap 62 depicted in FIG. 10 stems from a few key areas.
The first difficulty in rethreading is due to the fact that the
filament is inherently more flexible during threading when the end
is unsupported, than after it has been threaded and both ends are
fully supported and constrained. More specifically, the bending
mode is second order when rethreaded, which is inherently stiffer,
and less prone to bending or buckling, than a filament constrained
only at the upstream end corresponding to a first order bending
mode. Additionally, after the filament has been threaded, the
downstream portion serves to guide all the subsequent flowing
material into the tube. Finally, cutting a filament introduces
deformation to the feed material which may result in misalignment
of the filament and the receiving tube 64. This misalignment may
result in the filament not appropriately feeding into the receiving
tube 64 after cutting. This deformation can be minimized through
the use of stiff matrix material, and a sharp cutting blade.
However, blade wear, and the desire to use different types of
materials, means that in some applications it may be desirable to
use a different cutting mechanism or additional features to
increase threading reliability.
[0178] There are several ways to improve the reliability of
threading the filament past a cutting mechanism. For example, in
one embodiment, the gap 62 is selectively increased or decreased to
permit the introduction of the blade. In such an embodiment, when
not in use, the cutting mechanism 8 is removed from the gap 62 and
the guide tube 72 is displaced towards the receiving tube 64. This
reduces, and in some embodiments, eliminates the gap 62 during
rethreading. Alternatively, the guide tube 72 may be constructed
and arranged to telescope, such that a portion of the guide tube
moves towards the receiving tube 64 while another portion of the
guide tube stays fixed in place to reduce the gap. In another
embodiment, rethreading error is reduced using a flow of
pressurized fluid, such as air, that is directed axially down the
guide tube 72. The pressurized fluid exits the guide tube 72 at the
cutting mechanism 8 as depicted in the figure. Without wishing to
be bound by theory, as the continuous core filament 2, or other
appropriate material, is advanced through gap 62, the axial fluid
flow will center the material within the fluid flow thus aiding to
align the material with the receiving end 16. Such an embodiment
may also advantageously serve to cool the guide tube 72 tube during
use. This may help facilitate high-speed printing and/or higher
printing temperatures. The fluid flow may also help to reduce
friction of the material through the guide tube.
[0179] FIG. 12A depicts one embodiment of a shear cutting
mechanism. The shear cutting mechanism also eliminates the gap 62
of FIG. 10 which will increase the reliability of threading.
Similar to the above, the continuous filament 400 is driven in
compression by drive wheel 408, and received by a close-fitting
guide tube 420. The material is driven in compression through an
upper shear cutting block guide 406, lower shear cutting head 402,
and heated print head 404. The upper shear cutting block 406 and
lower shear cutting head 402 are displaced relative to each other
to apply a shearing force to the filament to cut it. While a
particular mechanism has been depicted in the figures, it should be
understood that any configuration capable of providing a shearing
force to the material might be used. For example, first and second
shearing elements may include aligned channels that are shaped and
size to accept a filament. The first and/or second shearing
elements may then be displaced relative to one another to take the
channels formed in the first and second shearing elements out of
alignment and apply a shear force to the filament to cut it.
Additionally, the shear cutting mechanism may located within a
print head, or upstream of the print head, as the disclosure is not
so limited.
[0180] FIG. 12B shows the upper shear cutting block 406 translated
relative to shear cutting head 402. As noted above, when the upper
shear cutting block is translated relative to the shear cutting
head, the filament segment 422 is sheared off from the continuous
filament 400. If a simple cut is desired, the shear head 402 can
return to the original position relative to the upper cutting block
406. In the presented diagram, the upper block moves. However,
either block, or both blocks, could move depending on the
particular design. The shear cut and return action is the simplest
cutting formation. After the shear cut and return, the end of the
filament 400 is entirely captive in the guiding tube. Therefore,
there is no gap to jump, thus, increasing the reliability of
feeding the filament forward for the next section of the part.
[0181] In addition to simply performing sheer cutting of a
material, in some embodiments, it may be desirable to provide
printing capabilities with multiple types of materials and/or
operations. FIG. 12A illustrates one embodiment of a system
including optional indexing stations 414 and 416. When shear head
402 is translated over to either station, a plurality of useful
operations can additionally occur. In one embodiment, station 416
is a cleaning station and includes a cleaning material 410, that
can be fed through the print head 404 to clean the nozzle. In one
example, the material is a metal like brass, copper, stainless
steel, aluminum, or the like. This enables the nozzle to be heated,
and purged with a material having a higher melting temperature than
the feed stock. In one embodiment, the print head 404 is moved to a
print cleaning station, for example, the back comer or other
appropriate location. The print head 404 is then heated up and
indexed to station 416. The cleaning material 410 is then fed
through the nozzle to clear any obstructions present. The shear
cutting action of the upper sheer cutting block 406 and the lower
shear cutting head 402 can then sever the sacrificial cleaning
pieces to prevent them from being dragged back up the nozzle, and
thereby introducing contaminants to the nozzle. In some instances,
however, the cleaning agent may be cyclically pushed down, and
pulled back up through the nozzle. In another embodiment, the
cleaning station 416 is used to push any number of cleaning agents
such as high-pressure air, liquids, solids, gasses, plasmas,
solvents or the like, through the nozzle in order to perform the
desired cleaning function.
[0182] In addition to the above, in some embodiments, the
three-dimensional printing system also includes a station 414
corresponding to a different material 412. Depending on the
particular application, the second material may be an electrically
conductive material such as copper, an optically conductive
material such as fiber optics, a second core reinforced filament,
plastics, ceramics, metals, fluid treating agents, solder, solder
paste, epoxies, or any other desired material as the disclosure is
not so limited. In such an embodiment, the print nozzle 404 is
indexed from one of the other stations to the station 414 to
deposit the second material 412. When the printing function using
the second material is finished, the print nozzle 404 is then
indexed from station 414 to the desired station and corresponding
material.
[0183] FIG. 13 shows a shear cutting block 402 including multiple
nozzles 404 and 424 formed in the shear cutting block. In one
embodiment, the nozzle 404 has a larger print orifice than the
nozzle 424, enabling larger diameter towpregs and/or pure polymer
materials to be deposited at a more rapid volume. In another
embodiment, the second nozzle 424 is substantially the same as
nozzle 404. Consequently, the second nozzle 424 may be used as a
replacement nozzle that can be automatically switched into use if
nozzle 404 becomes clogged. Having an additional nozzle would
decrease the down time of the machine, especially in unattended
printing (e.g. overnight). Similar to the above, the first and
second nozzles 404 and 424 may be indexed between different
stations.
[0184] FIG. 14A depicts a nozzle 500 including an inlet 502 and an
outlet 504. The geometry of the nozzle outlet 504 includes a sharp
exit comer. While some embodiments may use a nozzle with a sharp
corner at the outlet, a sharp corner may lead to cutting of fibers
in continuous core printing. Further, it may scrape off plating of
metal cores, and treatments applied to fiber optic cables
incorporated in a core. Consequently, in some embodiments, it is
desirable to provide a smooth transition at an outlet of a nozzle.
FIG. 14B depicts a chamfered nozzle outlet 506, which reduced shear
cutting of fibers in testing. Smoothly rounded nozzle exit 508
advantageously reduces shearing and cutting of non-molten
continuous cores. It should be appreciated that the particular
design of a transition at an outlet of a nozzle includes aspects
such as chamfer angle, fillet angle and degree, length of the
transition, and other appropriate considerations that will vary
depending on the particular material being used. For example,
Kevlar is extremely strong in abrasion, while fiberglass is weak.
Therefore, while a nozzle including a 45 degree chamfer may be
sufficient for Kevlar, it may result in broken strands when used
with fiber glass. However, by using additional chamfers, or other
features, it is possible to eliminate breakage of the fiberglass
cores during printing.
[0185] As depicted in the figures, nozzle outlet geometries 506 and
508 provide a smooth transition from the vertical to the horizontal
plane to avoid accidently cutting the core materials. However, in
some embodiments, it may be desirable to sever the continuous core
to cut the filament. One method of severing the continuous core at
the tip of the nozzle 500 is to push the nozzle down in the
vertical Z direction, as shown by arrow 210. As depicted in FIG.
14C, in some embodiments, the corner of the nozzle outlet 508 is
sharpened and oriented in the Z direction to enable the outlet to
sever the continuous core as the outlet impinges on and cuts
through the material. In order to facilitate cutting of the
material using such a method, it may be desirable to place the
material under tension. This tension may be provided in any number
of ways including, for example, providing a firm hold of the
material using the feeding mechanism, reversing the feeding
mechanism and/or moving the print head. Alternatively, the nozzle
500 might be kept stationary while the feeding mechanism is
reversed in order to pull the material against the edge of the
nozzle outlet and cut it. In another embodiment, the cutting can be
achieved by simply "breaking" the strand at the corner point where
it exits the nozzle by advancing the print head, without feeding,
thereby building tension until the core is severed. Typically this
will occur at the corner point of the nozzle exit. In this
embodiment, a compromise nozzle design may be selected. The nozzle
exit geometry may be slightly sharpened in order to enhance
cutting.
[0186] In another embodiment, a portion of a nozzle may be
sharpened and directed towards an interior of the nozzle outlet to
aid in cutting material output through the nozzle. As depicted in
in FIGS. 15A-15D, a nozzle 600 contains a continuous core filament
2, or other appropriate material, exiting from a chamfer style
nozzle. As depicted in the figures the nozzle 600 is smoothly
chamfered. Additionally, the nozzle 600 includes a ring 602 located
at a distal outlet of the nozzle. The majority of the ring 602 is a
non-cutting portion of the ring and is shaped and arranged such
that it does not interfere with material being output from the
nozzle. However, the ring 602 also includes a cutting portion 602a
which is sharpened and oriented inwards towards the material
contained within the nozzle 600, see FIGS. 15B-15D. Depending on
the particular embodiment, the cutting portion 602a is a sharp
cutting blade. The cutting portion may be made of a cutting steel,
a stainless steel, a carbide, a ceramic, or any appropriate
material. As illustrated in FIG. 15D, in some embodiments, the
cutting portion 602a occupies a fraction of the nozzle outlet area.
In such an embodiment, the cutting portion 602a may either be
permanently attached in the indicated position within the nozzle
outlet, or it may be selectively retracted during the printing
process and deployed into a cutting position when it is desired to
cut the printed material as the disclosure is not so limited.
Alternatively, in other embodiments, the cutting portion 602a is
recessed into a perimeter of the nozzle outlet such that it does
not impinge upon material exiting the nozzle during normal
operation. For example, the cutting portion 602a may form a part of
the perimeter of the nozzle exit as depicted in FIG. 15C. Other
arrangements of the cutting portion 602a relative to the nozzle
outlet are also contemplated. Additionally, while the cutting
portion 602a has been depicted as being incorporated with a ring
attached to a nozzle, embodiments in which the cutting portion is
either formed with the nozzle outlet and or directly attached to
the nozzle outlet are also contemplated.
[0187] With regards to the embodiment shown in FIGS. 15A-15D, when
it is desired to cut material being extruded from the nozzle, such
as, for example, the continuous core filament 2, the nozzle is
translated in a direction D relative to a part being constructed on
a surface, see the arrows depicted in the figures. During this
translation, the continuous core filament 2 is not fed through the
nozzle. Consequently, the continuous core filament 2, and the core
contained within it, is effectively held in place. This results in
the tensioning of the core material 6 which is displaced towards
the cutting portion 602a through the surrounding polymer matrix 4.
As increasing tension is applied to the continuous core filament 2,
the core 6 is cut through by the cutting portion 602a.
Alternatively, in some embodiments, the surface and/or part is
translated relative to the nozzle as the disclosure, or the
continuous core filament 2 is retracted using the feeding mechanism
to apply the desired tension to the core material 6 to perform the
severing action.
[0188] While a solid core with a particular size has been depicted
in the figures, it should be understood that the disclosure is not
so limited. Instead, such a cutting mechanism may be used with
solid cores, multi-filament cores, continuous cores,
semi-continuous cores, pure polymers, or any other desired
material. Additionally, the core material 6 may be any appropriate
size such that it corresponds to either a larger or smaller
proportion of the material depicted in the figures. In addition to
the above, for some materials, such as fiber optic cables, the
cutting portion 602a forms a small score in the side the core 6,
and additional translation of the nozzle relative to the part
completes the cut. For other materials, such as composite fibers,
the rounded geometry of the nozzle results in the core 6 being
directed towards the cutting portion 602a when it is placed under
tension as described above. Therefore, the resulting consolidation
(e.g. compaction) of the core towards the cutting portion enables
cutting of a large fiber with a relatively smaller section blade.
In yet another embodiment, the core 6 is either a solid metallic
core or includes multiple metallic strands. For example, the core
may be made from copper. In such an embodiment, the cutting portion
106a creates enough of a weak point in the material that sufficient
tensioning of the core breaks the core strand at the nozzle exit.
Again, tensioning of the core may be accomplished through nozzle
translation relative to the part, backdriving of the material, or a
combination thereof.
[0189] In yet another embodiment, the cutting portion 602a is a
high temperature heating element that heats the core in order to
sever it, which in some applications is referred to as a hot knife.
For example, the heating element might heat the core to a melting
temperature, carbonization temperature, or to a temperature where
the tensile strength of the core is low enough that it may be
broken with sufficient tensioning. It should be understood that,
the heating element may heat the core either directly or
indirectly. Additionally, in some embodiments, the element is a
high-bandwidth heater, such that it heats quickly, severs the core,
and cools down quickly without imparting deleterious heat to the
printed part. In one particular embodiment, the heating element is
an inductive heating element that operates at an appropriate
frequency capable of heating the core and/or the surrounding
material. In such an embodiment, the inductive heater heats the
core to a desired temperature to severe it. Such an embodiment may
be used with a number of different materials. However, in one
embodiment, an inductive heater is used with a continuous core
filament including a metallic core such as copper. The inductive
heating element heats the metallic core directly in order to severe
the strand. In instances where the heating element indirectly heats
the core, it may not be necessary to tension the material prior to
severing the core. Instead, the core may be severed and the nozzle
subsequently translated to break the material off at the nozzle
outlet.
[0190] FIG. 16 presents another embodiment of a nozzle tip-based
cutting mechanism m the depicted embodiment, a cutting element 604
is disposed on a distal end of the nozzle 600. While any
appropriate arrangement might be used, in the depicted embodiment a
cutting ring disposed around the distal end of the nozzle as
depicted in the figure. The cutting ring 604 includes a sharp and
edge oriented towards the deposited continuous core filament 2
depicted in the figure. In such an embodiment, the cutting element
604, or a subsection thereof, is actuated downwards towards the
deposited material in order to sever the core of the continuous
core filament 2. In another version, the internal nozzle 600 is
translated upwards relative to the cutting element 604. In such an
embodiment, the extrusion nozzle 600 may be spring loaded down.
Therefore, a cut can be executed by driving the feed head into the
part, thereby depressing the inner feed head, relative to the
cutting ring, and enabling the cutting ring to sever the core
material. In either case, the continuous core filament 2 is brought
into contact with the cutting element 604, and the core material 6
is severed.
[0191] While several different types of cutting mechanisms are
described above, it should be understood that any appropriate
cutting mechanism capable severing the core and/or surrounding
matrix might be used. Therefore, the disclosure should not be
limited to just the cutting mechanisms described here core the
particular core material and structure described in these
embodiments.
[0192] As noted above, tension-based three-dimensional printing
systems exhibit several limitations, including the inability to
make planar or convex shapes as well as difficulty associated with
threading the printed material through the system initially and
after individual cuts. In contrast, a compression-based
three-dimensional printing system offers multiple benefits
including the ability to make planar and convex shapes as well as
improved threading of the material. However, as noted previously,
in some modes of operation, and/or in some embodiments, material
may be deposited under tension by a system as the disclosure is not
so limited.
[0193] Referring again to FIG. 10, a three-dimensional printing
system may include a feeding mechanism such as a roller 40 capable
of applying a compressive force to the continuous core filament 2
fed into a printer head 70. However, as noted above, extruding a
towpreg, strand, fiber, or other similar material using a
compressive force may result in buckling. Consequently, it is
desirable to prevent buckling of the material when it is under
compression. Without wishing to be bound by theory, composite
fibers are incredibly stiff when constrained in place such as when
they are held in place by a matrix. However, composite fibers are
easily flexed when dry in a pre-impregnated form when they are not
constrained from moving in off axis directions. Therefore in some
embodiments, it is desirable to constrain movement of the material
in off axis directions. While this may be accomplished in a number
of ways, in one embodiment, and as noted above, one or more close
fitting guide tubes 72 are located between the feeding mechanism
and the receiving tube 64 or other inlet of the nozzle. The one or
more close fitting guide tubes 72 located along the fiber length
help to prevent buckling. The distance between the feeding
mechanism, such as the roller 40, and an inlet of the guide tube 72
may be selected to substantially avoid buckling of the material as
well. In some embodiments, it is desirable that the guide tubes are
close fitting and smooth such that their shape and size are
substantially matched to the continuous core filament 2. In one
specific embodiment, the guide tube is a round hypodermic tube.
However, embodiments in which the guide tube is sized and shaped to
accept an ovular, square, tape-like material, or any other
appropriately shaped material are also contemplated. In some
embodiments, and as described in more detail below, the continuous
core filament 2 may include a smooth outer coating and/or smface,
which is in contrast to tension wound systems where the core may
poke through the outer jacket. This smooth outer smface may
advantageously reduce the friction the material within the close
fitting guide tubes.
[0194] In some embodiments, the three-dimensional printing system
does not include a guide tube. Instead, the feeding mechanism may
be located close enough to an inlet of the nozzle, such as the
receiving tube 64, such that a length of the continuous core
filament 2 from the feeding mechanism to an inlet of the nozzle is
sufficiently small to avoid buckling. In such an embodiment, it may
be desirable to limit a force applied by the feeding mechanism to a
threshold below an expected buckling force or pressure of the
continuous core filament, or other material fed into the
nozzle.
[0195] In addition to depositing material using compression, the
currently described three dimensional printers may also be used
with compaction pressure to enhance final part properties. For
example, FIG. 17A shows a composite material, such as the
continuous core reinforced filament 2, that is extruded through a
printer head 60 with an applied compaction force or pressure 62.
The compaction pressure compresses the initial continuous core
reinforced filament 2a with an initial shape, see FIG. 17B, into
the preceding layer below and into a second compacted shape, see
FIG. 17C. The compressed continuous core reinforced filament 2b
both spreads into adjacent strands 2c on the same layer and is
compressed into the underlying strand of material 2d. This type of
compaction is typically achieved in composites through pressure
plates, or a vacuum bagging step, and reduces the distance between
reinforcing fibers, and increases the strength of the resultant
part. While the printer head 70 may be used to apply a compression
pressure directly to the deposited material other methods of
compressing the deposited materials are possible. For example the
deposited materials might be compacted using: pressure applied
through a trailing pressure plate behind the head; a full width
pressure plate spanning the entire part that applies compaction
pressure to an entire layer at a time; and/or heat may be applied
to reflow the resin in the layer and achieve the desired amount of
compaction within the final part.
[0196] As noted above, and referring to FIG. 18A, nozzles 700 used
in Fused Filament Fabrication (FFF) three dimensional printers
typically employ a constriction at the tip of the nozzle to trap
the solid, non-molten plastic when it first enters the nozzle at
inlet 702 and passes into the heated block 704. The converging
nozzle outlet 706 applies back-pressure, or retarding force, that
only enables material to pass through the nozzle once it has
melted, and can squeeze through the significantly smaller diameter
outlet 706. One of the problems associated with Fused Filament
Fabrication is the eventual clogging and jamming of the print head
(nozzle) due to the convergent nozzle design trapping material with
no means of ejecting it. Further, degraded plastic builds up within
the nozzle which eventually clogs the nozzle or alters the extruded
print bead. Additionally, in order to clean a convergent nozzle,
the feeding filament must be reversed backwards up through the
nozzle, potentially contaminating the feed path back to the
filament spool. After reversing through the entire feed path, the
contaminated tip of the feed material must be cut off from the feed
spool, and the spool must be re-threaded through the machine. For
these reasons, the nozzles on most FFF three-dimensional printers
are considered wear items that are replaced at regular
intervals.
[0197] Having realized these limitations associated with convergent
nozzles, the inventors have recognized the benefits associated with
a divergent nozzle. In a divergent nozzle, the inflowing material
expands as it transitions from the feed zone, to the heated melt
zone, thereby enabling any particulate matter that has entered the
feed zone to be ejected from the larger heated zone. Additionally,
a divergent nozzle is both easier to clean and may permit material
to be removed and a feed forward manner where material is removed
through the nozzle outlet as compared to withdrawing it through the
entire nozzle as described in more detail below.
[0198] FIG. 18B shows a nozzle 708 including a material inlet 710,
fluidly connected to cold-feed zone 712. In the depicted
embodiment, the inlet 710 and the cold feed zone 712 correspond to
a cavity or channel with a first size and shape. The cold feed zone
712 is disposed on top of him fluidly connected to a heated zone
714. A cross-sectional area of the cavity or channel depicted in
the heated zone 714 that is transverse to a path of the filament
when positioned therein is greater than a cross-sectional area of
the cavity or channel located in the cold-feed zone 712 that is
transverse to the path of the filament. Additionally, in some
embodiments, a cross-sectional area of the nozzle outlet transverse
to the path of the filament is greater than a cross-sectional area
of the nozzle inlet transverse to the path of the filament. The
nozzle also includes a nozzle outlet 716. During use, material
passes from the nozzle inlet 710, through the cold feed zone 712,
and into the heated zone 714. The material is then output through
the nozzle outlet 716. In some embodiments, the cold-feed zone 712
is constructed of a material that is less thermally conductive than
a material of the heated zone 714. This may permit the material to
pass through the cold feed zone 712 and into the heated zone 714
without softening. In one particular embodiment, a divergent nozzle
is formed by using a low-friction feeding tube, such as
polytetrafluoroethylene, that is fed into a larger diameter heated
zone located within a nozzle such that a portion of the heated zone
is uncovered downstream from the tube. Additionally, depending on
the embodiment, one or both of the cool feeding zone and heating
zone may be constructed from, or coated with, a low friction
material such as polytetrafluoroethylene. While a sharp transition
between the cold feed zone and the heated zone has been depicted in
the figures, embodiments of a divergent nozzle in which there is a
gradual transition from a smaller inlet to a larger outlet are also
contemplated.
[0199] One of the common failure modes of FFF is the eventual creep
up of the molten zone into the cold feeding zone, called
"plugging". When the melt zone goes too high into the feed zone,
and then cools during printing, the head jams. Having a divergent
nozzle greatly reduces the likelihood of jamming, by enabling
molten plastic to be carried from a smaller channel, into a larger
cavity of the divergent nozzle. Additionally, as described below, a
divergent nozzle is also easier to clean.
[0200] FIG. 18C depicts an instance where a divergent nozzle 708
has been obstructed by a plug 718 that has formed within the heated
zone 714 and been removed. Advantageously, a divergent nozzle can
be cleaned using a forward-feeding cleaning cycle. In one
embodiment, a forward feeding cleaning cycle starts by extruding a
portion of plastic onto a print bed such that the plastic adheres
to the print bed. Alternatively, the system may deposit the
material onto a cleaning area located at a back of the printing
system away from the normal build platform or on any other
appropriate surface as the disclosure is not so limited. After
attaching to the surface, the system is cooled down to permit the
material located within the heated zone 714 to cool below the
melting temperature of the material. After solidification, the
print bed and nozzle are moved relative to each other to extract
the plug 718 from the nozzle 708. For example, the print bed might
be moved down in the z direction. Alternatively, a printer head
including the nozzle might be moved in a vertical z direction away
from the print bed. Additionally, in some embodiments, a feeding
mechanism associated with the feed material is driven to apply an
additional force to the material as the plug is pulled out of the
nozzle. Either way, the plug is then pulled out of the nozzle,
advantageously removing debris previously stuck to the wall, and is
done without having to retract the feed material from the nozzle
through the feed path. While any appropriate material may be used
with a divergent nozzle, in some embodiments, a divergent nozzle is
used with a material including nylon. This may be beneficial
because the coefficient of thermal expansion for nylon causes it to
pull away from the nozzle slightly during cooling and nylons
exhibit low coefficient of friction. Again, the use of
polytetrafluoroethylene within one, or both of the cold feed zone
and the heated zone, may help facilitate the easy removal of plugs
formed within the nozzle.
[0201] While a method of use in which the divergent nozzle is
cleaned by attaching a plug to a surface, in another embodiment, a
cleaning cycle is performed by simply extruding a section of
plastic into free air. The plastic may then be permitted to cool
prior to being removed by hand or using an automated process. When
the material is removed, any plug attached to that material is also
removed.
[0202] In another embodiment, a forward feeding cleaning cycle is
used with a slightly convergent nozzle. For example, convergent
nozzles with an outlet to inlet ratio of 60% or more might be used,
though other outlet to inlet ratios are also possible. The forward
extrusion cleaning method for such a nozzle includes extruding a
section of molten material, and optionally attaching it to the
print bed. The heated nozzle is then allowed to cool. During the
cooling process, the ejected portion of material is pulled such
that the material located within the heated zone is stretched,
thereby reducing a diameter of the material. The material may be
stretched to a degree such that the diameter of the material
located within the heated zone is less than a diameter of the
nozzle outlet. Additionally, once the material has cooled, further
pulling enables diameter contraction through the Poisson's ratio of
the material, thereby further facilitating removal of the remnant
located within the nozzle. In some embodiments, the material is
stretched by applying a force by hand, or other external means, to
the extruded material. In other embodiments where the material is
attached to a surface, the printer head and/or surface are
displaced relative to each other as noted above to apply a force to
the material to provide the desired structure. The above described
method enables the feed forward cleaning of a slightly convergent
nozzle to be cleaned with forward material flow.
[0203] While a divergent nozzle has been discussed above,
embodiments in which a straight nozzle is used for FFF printing are
also contemplated. FIG. 19A depicts a nozzle 720 including an inlet
724 that is substantially the same size as nozzle outlet 722. A
material such as a continuous core filament 2 passes through a cold
feed zone 712 and into a heated zone 714. In one embodiment, the
cold feed zone is a low friction cold-feed zone made from a
material with a low coefficient of thermal conduction such as
polytetrafluoroethylene. Correspondingly, the heated zone 714 is
made from a more thermally conductive material such as copper,
stainless steel, brass, or the like. Regardless of the specific
construction, after melting, the continuous core filament 2 is
deposited on, and attached to, a build platen 16 or other
appropriate surface. Straight nozzles are ideally suited to small
diameter filaments, on the order of about 0.001'' up to 0.2''.
However, embodiments in which materials with diameters both greater
than and less than those noted above are used with a substantially
straight nozzle are also contemplated. Without wishing to be bound
by theory, the low thermal mass associated with these small
filaments permits them to heat up quickly. Additionally, the small
dimensions permit these materials to be extruded at substantially
the same size as they are fed into the print head. Similar to a
divergent nozzle, a substantially straight nozzle offers the
advantages of forward feeding cleaning cycles that enables a cooled
plug to be removed from the tip and substantially avoiding
collecting particles and debris within the nozzle.
[0204] A nozzle similar to that described in FIG. 19A can also be
used with a typical green towpreg 734. However, this may result in
clogging similar to typical three dimensional printing systems
using a green towpreg. The clogging is a result of trying to "push"
a flexible composite strand through a nozzle in the initial
stitching operation. FIG. 19B illustrates what happens when a green
towpreg is output through nozzle 720 during an initial stitching
operation to attach it to a part or build plate. Namely, instead of
being pushed through the nozzle as intended, the individual fibers
in the green towpreg 734 tend to stick to the walls of the nozzle
and commensurately start to bend and curl up at 736. Put another
way, the flexible fibers located within a green or flexible towpreg
are likely to delaminate and become clogged in the nozzle. Flexible
materials may include, but are not limited to, a molten
thermoplastic and/or un-cured plastic for two part mixed epoxy or
laser cured resins, though other flexible materials are also
possible.
[0205] In contrast to the above, a stitching process associated
with a preimpregnated continuous core filament within a divergent
nozzle does not suffer the same limitations. More specifically,
FIGS. 19C-19E illustrate a method of stitching using a rigid
preimpregnated continuous core filament fed through a divergent
nozzle, such that clogging is reduced, or substantially eliminated.
FIG. 19C shows a continuous core filament 2 located within the cold
feed zone 712. Depending on the particular embodiment, the material
may be located on the order of 5 inches or more from the heated
zone 714, though other distances are also contemplated.
Additionally, in embodiments where the material has a larger
thermal capacity and/or stiffness, it may be located closer to the
heated zone 714 to provide pre-heating of the material prior to
stitching. While located within the cold feed zone 712, which is
below a melting temperature of the matrix, the continuous core
filament 2 remains substantially solid and rigid. The continuous
core filament 2 is maintained in this position until just prior to
printing. At that point, the continuous core filament 2 is quickly
stitched through the nozzle, i.e. displaced through the nozzle
outlet, see FIG. 19D. Since the cold-feed zone 712 feeds into a
larger cavity corresponding to the heated zone 714, when the
material is stitched, the continuous core filament 2 is constrained
from touching the walls of the heated zone 714 by portion of the
filament still located in the outlet of the cold feed zone, see
FIG. 19D. By performing the stitching quickly, melting of the
matrix may be minimized to maintain a stiffness of the composite
material. By maintaining a stiffness of the material and preventing
melting until the material has been stitched, it is possible to
prevent fibers from peeling off, curling and/or clogging within the
nozzle. This may enable the feed material to be more easily pushed
into, and through, the hot-melt zone. In some embodiments, a blast
of compressed air may be shot through the nozzle prior to and/or
during stitching in order to cool the nozzle to reduce the chance
of sticking to the sides of the nozzle. Additionally, heating of
the heated zone 714 of the nozzle may be reduced or eliminated
during a stitching process to also reduce the chance of sticking to
the sides of the nozzle.
[0206] As feeding of the continuous core filament 2 continues, the
continuous core filament 2 eventually contacts the build platen 16,
or other appropriate surface. The continuous core filament 2 is
then dragged across the surface by motion of the nozzle relative to
the build platen 16. This results in the continuous core filament 2
contacting the walls of the heated zone 714 as illustrated in FIG.
19E. Alternatively, instead of translating the printer head, the
material could be driven to a length longer than a length of the
nozzle. When the outlet of the nozzle is blocked by a previous
layer of the part, or by the print bed, the material will buckle
and contact the walls of the heated zone 714. Regardless of the
particular method employed, after contacting the walls of the
heated zone 714, the continuous core filament 2 is heated up to a
desired deposition temperature capable of fusing the deposited
material to a desired surface and/or underlying previously
deposited layers thus enabling three-dimensional printing. For
example, once translation of the print head begins, the matrix
material contacts a wall of the heated zone and is heated to a
melting temperature of the matrix material. Stitching speeds
obtained with a system operated in the manner described above, was
capable of stitching speeds between about 2500 mm/min and 5000
mm/min. However, the stitching speed will vary based on nozzle
heating, matrix material, and other appropriate design
considerations. While a particular stitching method has been
described above, it should be noted that other types of stitching
and melting techniques could also be employed as the disclosure is
not limited to any particular technique.
[0207] As also depicted in FIGS. 19C-19E, in some embodiments, the
nozzle 708 may include a rounded or chamfered lip 726, or other
structure, located at a distal end of the nozzle outlet 716. This
may serve two purposes. First, as noted previously, a gradual
transition at the nozzle outlet may help to avoid fracturing of the
continuous core. Additionally, in some embodiments, the lip 726 is
positioned such that the lip applies a downward force to the
continuous core filament 2 as it is deposited. This may in effect
applying a compaction force to the material as it is deposited
which may "iron" the continuous core filament down to the previous
layer. As noted above compaction forces applied to the material may
offer multiple benefits including increased strength and reduced
void space to name a few. This compaction force may be provided by
positioning the lip 726 at a distance relative to a deposition
surface that is less than a diameter of the continuous core
filament 2. However, compaction forces provided using distances
greater than a diameter of the continuous core filament are also
possible for sufficiently stiff materials. This distance may be
confirmed using an appropriate sensor, such as a range finder as
noted above. In some embodiments, the lip 726 is incorporated with
a substantially straight nozzle 720 or a slightly convergent nozzle
as the disclosure is not so limited, see FIG. 20A.
[0208] While the above embodiments have been directed to divergent
and straight nozzles including a cold feed zone and a separate
heated zone, embodiments in which a convergent nozzle includes a
separate cold feed zone and heated zone are also contemplated. For
example, FIG. 20B shows an nozzle 728 including a nozzle inlet 730
that feeds into a cold feed zone 712 which is in fluid
communication with a heated zone 714. The heated zone 714 is
incorporated with a convergent nozzle outlet 732.
[0209] In embodiments using a high-aspect ratio convergent nozzle,
it may be desirable to use a nozzle geometry that is optimized to
prevent the buildup of feed material and/or to reduce the required
feed pressure to drive the material through the nozzle outlet. FIG.
21A shows a typical FFF nozzle 800 including an inlet 806 that is
aligned with an internal wall 802. The internal wall 802 extends up
to a convergent section 804 that leads to a nozzle outlet 808 with
an area that is less than an area of the inlet 806. FIGS. 21B-21D
depict various geometries including smooth transitions to reduce a
back pressure generated within the nozzle.
[0210] In one embodiment, as depicted in FIG. 21B, a nozzle 810
includes an inlet 806 and an internal wall 812 with a first
diameter. Initially, the internal wall 812 is vertical and
subsequently transitions to a tangential inward curvature 814.
After about 45 degrees of curvature, an inflection point 816 occurs
and the internal wall reverses curvature and curves until the
internal wall 812 is vertical. The resulting nozzle outlet 818 is
aligned with the inlet 810, but has a reduced second diameter.
Additionally, the resulting exit flow from the outlet will be
aligned with the inlet flow, though flows through the outlet that
are not aligned with the inlet are also contemplated.
[0211] When a lower degree of alignment of polymer chains is
desirable, the first inward curving section 814 depicted in FIG.
21B can be eliminated, such that the final geometry that turns the
flow back into the extruded direction does so after a more typical
chamfered inlet. One such embodiment is depicted in FIG. 21C. As
depicted in the figure, a nozzle 820 includes an internal wall that
transitions to a downwards oriented curvature 822 directed towards
the nozzle outlet 824. FIG. 4D depicts another embodiment in which
a nozzle 826 transitions to a standard chamfered nozzle section 828
which extends up to a point 830 where it transitions to a downwards
oriented curvature 832 to define a nozzle outlet 834. While
particular nozzle geometries have been depicted in figures and
described above, should be understood that other types of nozzle
geometries might also be used as the disclosure is not so
limited.
[0212] In some embodiments, a nozzle includes one or more features
to prevent drips. For example, a nozzle may include appropriate
seals such as one or more gaskets associated with a printing nozzle
chamber to prevent the inflow of air into the nozzle. This may
substantially prevent material from exiting the nozzle until
material is actively extruded using a feeding mechanism. In some
instances, it may be desirable to include other features to prevent
dripping from the nozzle as well while printing is stopped. In one
specific embodiment, a nozzle may include a controllable heater
that can selectively heat the nozzle outlet to selectively start
and stop the flow of material form the nozzle. In this regard, a
small amount of the resin near the outlet may solidify when the
heater is power is reduced to form a skin or small plug to prevent
drooling from the outlet. Upon reenergizing or increasing the
heater power, the skin/plug re-melts to allow the flow of material
from the nozzle. In another embodiment, the nozzle includes
features to selectively reduce the pressure within the nozzle to
prevent dripping. This can be applied using a vacuum pump, a closed
pneumatic cylinder, or other appropriate arrangement capable of
applying suction when nozzle dripping is undesirable. The pneumatic
cylinder is then returned to a neutral position, thus eliminating
the suction, when printing is resumed. FIG. 22 depicts one such
embodiment. In the depicted embodiment, an extrusion nozzle 900 has
a material 902 that is fed past one or more gaskets 910 and into a
cold feed zone 914 and heated zone 912 prior to exiting nozzle
outlet 908. An air channel 904 is connected to the cold feed zone
914 and is in fluid communication with a pneumatic cylinder 906. As
depicted in the figure, a gap is present between the material 902
and the cold feed zone 914 through which air may pass. Therefore,
the air channel 904 is in fluid communication with both the cold
feed zone 914 as well as with material located within the heated
zone 912. During operation, the pneumatic cylinder 906 is actuated
from a first neutral position to a second position to selectively
applying suction to the air channel 904 when printing is stopped.
Since the air channel 904 is in fluid communication with material
within the heated zone 912, the suction may substantially prevent
dripping of polymer melt located within the heated zone. Once
printing resumes, the pneumatic cylinder 906 may be returned to the
neutral position.
[0213] While various embodiments of nozzles in cutting mechanisms
are described above, in some embodiments, it is desirable to use a
towpreg, or other material, that does not require use of a cutting
mechanism to cut. In view of the above, the inventors have
recognized the benefits associated with using a material including
a semi-continuous core strand composite with a three-dimensional
printer. In such an embodiment, a material including a
semi-continuous core has a core that has been divided into
plurality of discrete strands These discrete strands of the core
may either correspond to a solid core or they may correspond to a
plurality of individual filaments bundled together as the
disclosure is not so limited. Additionally, as described in more
detail below, these discrete segments of the core may either be
arranged such that they do not overlap, or they may be arranged in
various other configurations within the material. In either case,
the material may be severed by applying a tension to the material
as described in more detail below. The tension may be applied by
either backdriving a feed mechanism of the printer and/or
translating a printer head relative to a printed part without
extruding material from the nozzle.
[0214] In one embodiment a material including semi-continuous core
includes segments that are sized relative to a melt zone of an
associated three-dimensional printer nozzle such that the
individual strands may be pulled out of the nozzle. For example,
the melt zone could be at least as long as the strand length of the
individual fibers in a pre-preg fiber bundle, half as long as the
strand length of the individual fibers in a pre-preg fiber bundle,
or any other appropriate length. In such an embodiment, at the
termination of printing, the material including a semi-continuous
core is severed by tensioning the material. During tensioning of
the material, the strands embedded in material deposited on a part
or printing surface provide an anchoring force to pull out a
portion of the strands remaining within the nozzle. When the
individual strands are appropriately sized relative to a melt zone
of the nozzle as noted above, strands that are located within both
the extruded material and with the nozzle are located within the
melt zone of the nozzle. Consequently, when tension is applied to
the material, the segments located within the melt zone are pulled
out of the melt zone of the nozzle to sever the material. In
embodiments where longer strands are used, instances where at least
some strands are pulled out of a molten zone of the deposited
material and retained within the nozzle are also contemplated. The
above noted method may result in vertically oriented strands of
core material. This vertical strands may optionally be pushed over
by the print head, or they are subsequently deposited layers. By
strategically placing vertically oriented strands within a material
layer, it may be possible to increase a strength of the resulting
part in the z direction by providing enhanced bonding between the
layers.
[0215] In another embodiment, a semi-continuous core embedded in a
corresponding matrix material includes a plurality of strands that
have discrete, indexed strand lengths. Therefore, termination of
the semi-continuous core occurs at pre-defined intervals along the
length of the material. Initially, since the terminations are
located at predefined intervals, the strand length may be larger
than a length of the melt zone of an associated nozzle. For
example, in one specific embodiment, a semi-continuous core might
include individual strands, or strand bundles, that are arranged in
3-inch lengths and are cleanly separated such that the fibers from
one bundle do not extend into the next. When using such a material,
a three-dimensional printer may run a path planning algorithm to
lineup breaks in the strand with natural stopping points in the
print. In this embodiment, there is a minimum fill size which
scales with the semi-continuous strand length because the printer
cannot terminate the printing process until a break in the
semi-continuous strand is aligned with the nozzle outlet.
Therefore, as the strand length increases, in some embodiments, it
may be advantageous to fill in the remainder of the layer with pure
resin which has no minimum feature length. Alternatively, a void
may be left in the part. In many geometries, the outer portion of
the cross section provides more strength than the core. In such
cases, the outer section may be printed from semi-continuous
strands up until the last integer strand will not fit in the
printing pattern, at which point the remainder may be left empty,
or filled with pure resin.
[0216] In another embodiment, a material may include both of the
above concepts. For example, indexed continuous strands may be
used, in parallel with smaller length bundles located at transition
points between the longer strands, such that the melt zone in the
nozzle includes sufficient distance to drag out the overlapping
strands located in the melt zone. The advantage of this approach is
to reduce the weak point at the boundary between the longer integer
continuous strands. During severance of a given core and matrix
material, it is desirable that the severance force is sufficiently
low to prevent part distortion, lifting, upstream fiber breaking,
or other deleterious effects. In some cases, strands may be broken
during the extraction, which is acceptable at the termination
point. While the strand length can vary based on the application,
typical strand lengths may range from about 0.2'' up to 36'' for
large scale printing.
[0217] FIGS. 23A-24D depict various embodiments of a
semi-continuous core filament being deposited from a nozzle. As
contrasted to the continuous core filament 2 depicted in FIG.
24A.
[0218] As depicted in the FIG. 23A, a semi-continuous core filament
1000 including a first strand 1002 and a second strand 1004 located
within the matrix material 1006. The semi-continuous core filament
1000 enters a cold feeding zone 712 of a nozzle which is
advantageously below the glass transition temperature of the matrix
material. The semi-continuous material 1000 subsequently flows
through heated zone 714, sometimes referred to as a melt zone. The
matrix material 1006 present in the semi-continuous material 1000
is melted within the heated zone 714 prior to deposition. Upon exit
from the nozzle, semi-continuous core filament 1000 is attached to
a part or build platen 16 at anchor point 1005. The severance
procedure can then occur in a number of ways. In one embodiment,
severance occurs by moving the print head forward relative to the
anchor point 1005, without advancing the semi-continuous core
filament 1000. Alternatively, the print head may remain stationary,
and the upstream semi-continuous core filament 1000 is retracted to
apply the desired tension. Again by appropriately sizing the strand
length to a length of the heated zone to ensure that an entire
length of the strand located within the nozzle is in the heated
zone 714, the tension provided by the anchor point 1005 permits the
remaining portion of the second strand 1004 located within the
nozzle to pull the remnant of the embedded strand from the heated
nozzle.
[0219] While FIG. 23A showed two individual strands, FIGS. 23B and
24B show a semi-continuous core filament 1008 including a
distribution of similarly sized strands 1010 embedded in a matrix
material 1006 and located in a printer head similar to that
described above. While three strands are shown in a staggered line,
it should be understood that this is a simplified representation of
a random, or staggered, distribution of strands. For example,
material may include about 1,000 strands of carbon fiber (a 1 k
tow). While a distribution of strand lengths 1015 and positioning
of the individual strands is to be expected, the strands 214 may be
sized and distributed such that there are many overlapping strands
of substantially similar length. By ensuring that heated zone 714
is proportional to a strand length 1015, the fiber remnant can be
more easily pulled from the nozzle. For example, and without
wishing to be bound by theory, the strands that are located further
downstream, i.e. mostly deposited within a part, will pull out from
the nozzle easily. The strands that are mostly located in the
nozzle will most likely remain within the nozzle. The strands that
are half in the nozzle, and half out, will stochastically stay in
the nozzle or get pulled out by the anchor point 1005 due to the
roughly equivalent forces being applied to roughly equivalent
lengths of the strands contained within the deposited material and
the nozzle. The various parameters of the nozzle design such as the
design of the cold feeding zone 714 and the nozzle outlet
transition as well as the viscosity of the polymer melt, the degree
of cooling of the printed semi-continuous core filament upon exit
from the nozzle outlet, as well as other appropriate considerations
will determine how the semi-continuous core filament is severed
when a tension is applied to the material.
[0220] FIGS. 23C and 24C shows an indexed semi-continuous core
filament 1012 where the termination of the core material is
substantially complete at each section, thereby enabling clean
severance at an integer distance. As depicted in the figures, the
material includes individual sections of one or more core segments
1014 embedded within a matrix material 1006. The individual
sections of core material are separated from adjacent sections of
core material at pre-indexed locations 1016. Such an embodiment
advantageously permits the clean severance of the material at a
prescribed location. This is facilitated by the individual strands
in different sections not overlapping with each other. This also
enables the use of strand lengths that are larger than a length of
the associated heated zone 714 of the nozzle. This also permits use
of the smaller heated zone 714 in some embodiments. However, in
addition to the noted benefits, since the individual strands in
different sections do not overlap, the material will exhibit a
reduced strength at these boundary locations corresponding to the
pre-indexed locations 1016 depicted in the figures. FIG. 25
illustrates the use of such a semi-continuous core filament. As
depicted in the figure, multiple strands 1100 are deposited onto a
part or build platen. The strands 1100 are deposited such that they
form turns 1102 as well as other features until the print head
makes it final pass and severs the material at 1104 as described
above. Since the individual strands are longer than the remaining
distance on the part, the remaining distance 1106 may either be
left as a void or filled with a separate material such as a
polymer.
[0221] FIG. 24D shows an example of a hybrid approach between a
semi-continuous core filament and a continuous core filament. In
the depicted embodiment, a material 1018 includes multiple discrete
sections including one or more core segments 1014 embedded within a
matrix 1006 that are located at pre-indexed locations similar to
the embodiment described above in regards to FIGS. 24C and 25C. The
material also includes a continuous core 1020 embedded within the
matrix 1006 extending along a length of material. The continuous
core 1020 may be sized such that it may be severed by a sufficient
tensile force to enable severing of the material at the pre-indexed
locations simply by the application of a sufficient tensile force.
Alternatively, any of the various cutting methods described above
might also be used.
[0222] While the above embodiments have been directed to materials
that may be severed without the use of a cutting mechanism. It
should be understood that semi-continuous core filaments may also
be used with three dimensional printing systems including a cutting
mechanism as the disclosure is not so limited.
[0223] In traditional composite construction successive layers of
composite might be laid down at 0.degree., 45.degree., 90.degree.,
and other desired angles to provide the part strength in multiple
directions. This ability to control the directional strength of the
part enables designers to increase the strength-to-weight ratio of
the resultant part. Therefore, in another embodiment, a controller
of a three dimensional printer may include functionality to deposit
the reinforcing fibers with an axial alignment in one or more
particular directions and locations. The axial alignment of the
reinforcing fibers may be selected for one or more individual
sections within a layer, and may also be selected for individual
layers. For example, as depicted in FIG. 26 a first layer 1200 may
have a first reinforcing fiber orientation and a second layer 1202
may have a second reinforcing fiber orientation. Additionally, a
first section 1204 within the first layer 1200, or any other
desired layer, may have a fiber orientation that is different than
a second section 1206, or any number of other sections, within the
same layer.
[0224] The concept of providing axial orientation of the
reinforcing fibers to provide directional strength within the part
may be taken further with three dimensional printers. More
specifically, FIGS. 27A-27C show a method of additive manufacturing
of an anisotropic object with a printer head 1310, such as an
electric motor or other part that may benefit from anisotropic
properties. In the depicted embodiment, a part 1300 has a
vertically oriented subcomponent 1302 that is printed with the part
oriented with Plane A aligned with the XY print plane in a first
orientation. In this particular example, the printed material
includes a conductive core such that the printed subcomponent 1302
forms a wound coil of a motor. In the depicted embodiment, the
coils are wound around the Z direction. While a particular material
for use in printing a motor coil is described, it should be
understood that other materials might be used in an anisotropic
part for any number of purposes as the current disclosure is not
limited to any particular material or application.
[0225] In order to form another coil, or other anisotropic
subcomponent, on the part 1300, a fixture 1304, shown in FIG. 27B,
is added to the print area though embodiments in which this feature
is printed during, before, or after the formation of part 1300 are
also possible. In one embodiment, the fixture 1304 is positioned
at, or below, the print plane 1306 and is contoured to hold the
part 1300 during subsequent deposition processes. The fixture may
also include vacuum suction, tape, mechanical fasteners, printed
snap fits, or any other appropriate retention mechanism to further
hold the part during subsequent print processes.
[0226] After positioning the fixture 1304, the part 1300 is
positioned on fixture 1304, which then holds the part 1300 in a
second orientation, with plane A rotated to plane A' such that the
next subcomponent 1308 can be added to the part 1300. The
subcomponent 1308 is again deposited in the Z direction, but is out
of plane with subcomponent 1302, as shown in FIG. 27C. While this
example has been described with regards to forming the coiled
windings of a motor, any anisotropic object could be formed using a
series of fixture rotations of the part, or print head, to enable
the continuous core reinforced filaments to be aligned in an
optimal direction for various purposes.
[0227] FIG. 28A shows the same anisotropic part as formed in the
process described in FIGS. 27A-27C, however, instead of making use
of a plurality of fixtures, the three dimensional printer is
capable of rotating the part 1300 as well as the printer head 1310
about one or more axes. As depicted in the figure, part 1300 is
held in place by a rotating axis 1312, which sets and controls the
orientation of plane A. In FIG. 28B, rotating axis 1312 has been
rotated by 90.degree. to form subcomponent 1308 in a direction that
is perpendicular to subcomponent 1302. Conversely, printer head 510
could be pivoted about the XT and/or yT axes to achieve a similar
result. As FIGS. 28A-28B show, there are many ways to achieve
anisotropic printing. Namely, the part may be moved and rotated,
the printer head may be moved and rotated, or a combination of both
may be used to print an anisotropic part. It should be understood,
that additional degrees of freedom could be added to either the
rotation and movement of the part 1300 or the printer head 1310
based on the machine objectives, and part requirements. For
example, in an automotive application, rotating axis 1312 may
correspond to a rotisserie, enabling rotation of the vehicle frame
about the yT axis to enable continuous fibers to be laid in the X-Y
plane, the Z-Y plane, or any plane in between. Alternatively, a
fluid rotation following the external contours of the vehicular
body might be used to continuously deposited material on the
vehicle as it is rotated. Such a three dimensional printer might
optionally add the XT axis to the printer head to enable full
contour following as well as the production of both convex and
concave unibody structures.
[0228] In addition to rotating the part 1300 and the printer head
1310, in some embodiments, a table 1314 supporting the part 1300
could be rotated about the ZT axis to enable spun components of a
given fiber direction. Such an embodiment may provide a consistent
print arc from the print head to the part for core materials that
have unique feeding and deposition head requirements that prefer
directional consistency.
[0229] In another embodiment, the core of a part may be built up as
a series of two dimensional planes. The three-dimensional printer
may then form, out of plane three dimensional shells over the
interior core. The core supports the shells which enables the
shells to be constructed on the outside of the core and may run up
the sides of the part, over the top, and/or down the back sides of
the part, or along any other location. Without wishing to be bound
by theory, such a deposition method may aid in preventing
delimitation and increase torsional rigidity of the part due to the
increased part strength associated with longer and more continuous
material lengths. Further running the continuous fiber reinforced
materials out of plane provides an out-of-plane strength that is
greater than a typical bonded joint.
[0230] FIG. 29 shows a three dimensional printer head 1310 similar
to that described above in regards to FIGS. 28A and 28B that can be
used to form a part including a three dimensionally printed shell.
The printer head 1310 deposits any appropriate consumable material
such as a continuous core reinforced filament 2 onto the built
platen 1314 in a series of layers 1320 to build a part. The printer
head 1310 is capable of articulating in the traditional XYZ
directions, as well as pivoting in the XT yT and zT directions. The
additional degrees of freedom to pivot the printer head 1310 allow
the printer to create shells, and other contiguous core reinforced
out of plane layers, as well as two dimensional layers.
[0231] FIGS. 30A-30C depict various parts formed using the printer
head depicted in FIG. 29. FIG. 30A shows a part including a
plurality of sections 1322 deposited as two dimensional layers in
the XY plane. Sections 1324 and 1326 are subsequently deposited in
the ZY plane to give the part increased strength in the Z
direction. FIG. 30B show a related method of shell printing, where
layers 1328 and 1330 are formed in the XY plane and are overlaid
with shells 1332 and 1334 which extend in both the XY and ZY
planes. As depicted in the figure, the shells 1332 and 1334 may
either completely overlap the underlying core formed from layers
1328 and 1330, see portion 1336, or one or more of the shells may
only overly a portion of the underlying core. For example, in
portion 1338 shell 1332 overlies both layers 1328 and 1330.
However, shell 1334 does not completely overlap the layer 1328 and
creates a stepped construction as depicted in the figure. FIG. 30C
shows another embodiment where a support material 1340 is added to
raise the part relative to a build platen, or other supporting
surface, such that the pivoting head of the three dimensional
printer has clearance between the part and the supporting surface
to enable the deposition of the shell 1342 onto the underlying
layers 1344 of the part core.
[0232] The above described printer head may also be used to form a
part with discrete subsections including different orientations of
a continuous core reinforced filament. For example, the orientation
of the continuous core reinforced filament in one subsection may be
substantially in the XY direction, while the direction in another
subsection may be in the XZ or YZ direction. Such multi-directional
parts enable the designer to run reinforcing fibers exactly in the
direction that the part needs strength.
[0233] The high cost of composite material has been one of the
major barriers to widespread adoptions of composite parts.
Therefore, in some embodiments a three dimensional printer may
utilize a fill pattern that uses high-strength composite material
in selected areas and filler material in other locations, see FIGS.
30D-300. Consequently, in contrast to forming a complete composite
shell on a part is described above, a partial composite shell is
formed on the outer extremes of a part, to maximize the stiffness
of the part for a given amount of composite material used. Low-cost
matrix material such as nylon plastic may be used as the fill-in
material, though other materials may also be used. A part formed
completely from the fill material 1350 is depicted in FIG. 30D. As
illustrated in FIG. 30E, a composite material 1352 is deposited at
the radially outward most portions of the part and extending
inwards for a desired distance to provide a desired increase in
stiffness and strength. The remaining portion of the part is formed
with the fill material 1350. Alternatively, portions of the build
plane may be left unfilled. Depending on the desired strength
and/or stiffness, a user may increase or decrease an amount of the
composite material 1352 used. This will correspond to the composite
material extending either more or less from the various corners of
the part. This variation in amount of composite material 1352 is
illustrated by the series of figures FIGS. 30D-300.
[0234] When determining an appropriate fill pattern for a given
level of strength and stiffness, a control algorithm starts with a
concentric fill pattern that traces the outside corners and wall
sections of the part, for a specified number of concentric infill
passes, the remainder of the part may then be filled using a
desired fill material. The resultant structure maximizes the
strength of the part, for a minimum of composite usage. It should
be understood that while the above process is described for a two
dimensional plane, it is also applicable to three dimensional
objects as well.
[0235] FIGS. 31A-31C show the cross-sections of various embodiments
of an airfoil with different fiber orientations within various
subsections. It should be understood that while an airfoil as
described below, the described embodiments are applicable to other
applications and constructions as well.
[0236] FIG. 31A shows a method of building each section of the
three dimensional part with plastic deposition in the same plane.
Specifically, sections 1350, 1352 and 1354 are all constructed in
the same XY planer orientation. The depicted sections are attached
at the adjoining interfaces, the boundary of which is exaggerated
for illustration purposes. In another embodiment, and as depicted
in FIG. 31B, a part is constructed with separate sections 1362,
1364, and 1366 where the fiber orientations 1368 and 1372 of
sections 1362 and 1366 are orthogonal to the fiber orientation 1370
of section 1364. Without wishing to be bound by theory, by
orthogonally orienting the fibers in section 1364 relative to the
other sections, the resulting part has a much greater bending
strength in the Z direction. Further, by constructing the part in
this manner, the designer can determine the relative thickness of
each section to prescribe the strength along each direction.
[0237] FIG. 31C depicts a shell combined with subsections including
different fiber orientations. In this embodiment, sections 1374,
1376, and 1378 are deposited in the same direction to form a core,
after which a shell 1386 is printed in the orthogonal direction.
The shell 1386 may be a single layer or a plurality of layers.
Further, the plurality of layers of shell 1386 may include a
variety of orientation angles other than orthogonal to the
underlying subsections of the core, depending on the design
requirements. While this embodiment shows the inner sections with
fiber orientations all in the same direction 1380, 1382, and 1384,
it should be obvious that subsections 1374, 1376, and 1378 may be
provided with different fiber orientations similar to FIG. 31B as
well.
[0238] In other embodiments, the continuous core reinforced
filament, or other appropriate consumable material, may require a
post-cure, such that the part strength is increased by curing the
part. Appropriate curing may be provided using any appropriate
method including, but not limited to, heat, light, lasers, and/or
radiation. In this embodiment, a part may be printed with a
pre-preg composite and subject to a subsequent post-cure to fully
harden the material. In one specific embodiment, continuous carbon
fibers are embedded in a partially cured epoxy such that the
extruded component sticks together, but requires a post-cure to
fully harden. It should be understood that other materials may be
used as well.
[0239] FIG. 32 depicts an optional embodiment of a three
dimensional printer with selectable printer heads. In the depicted
embodiment, a print arm 1400 is capable of attaching to printer
head 1402 at universal connection 1404. An appropriate consumable
material 1406, such as a continuous core reinforced filament, may
already be fed into the printer head 1402, or it may be fed into
the printer after it is attached to the printer 1400. When another
print material is desired, print arm 1400 returns printer head 1402
to an associated holder. Subsequently, the printer 1400 may pick up
printer head 1408 or 1410 which are capable of printing consumable
materials that are either different in size and/or include
different materials to provide different. As depicted, such
swappable printer heads are used one at a time, and advantageously
reduce the mass of the printer head and arm combination. Without
wishing to be bound by theory, this enables faster printing of a
part due to the reduced inertia of the printer head. In another
embodiment, the print arm may have slots for two or more printer
heads concurrently. Such heads may feed different material, apply
printed colors, apply a surface coating of spay deposited material,
or the like. It should be understood that any number of separate
selectable print heads might be provided. For example, the print
heads may be mounted to a turret, with one print head in the
"active" position and the others rotated out of position awaiting
for the appropriate time when they may be rotated into the print
position. In another embodiment, print arm may 1400 pick up a
vision system 1412 for part inspection. Appropriate vision systems
include cameras, rangefinders, or other appropriate systems.
[0240] While most of the above embodiments are directed to the use
of preformed continuous core reinforced filaments, in some
embodiments, the continuous core reinforced filament may be formed
by combining a resin matrix and a solid continuous core in the
heated extrusion nozzle. The resin matrix and the solid continuous
core are able to be combined without the formation of voids along
the interface due to the ease with which the resin wets the
continuous perimeter of the solid core as compared to the multiple
interfaces in a multifilament core. Therefore, such an embodiment
may be of particular use where it is desirable to alter the
properties of the deposited material. Further, it may be especially
beneficial to selectively extrude one or more resin matrices,
continuous cores, or a combination thereof to deposit variety of
desired composite structures.
[0241] FIG. 33 depicts a multi-element printer head 1500 that is
capable of selectively extruding material feed options 1502, 1504,
and 1506 as well as an optional cutting mechanism 8. More
specifically, the multi-element printer head 1500 is capable of
selectively depositing any of material feed options 1502, 1504, and
1506, as singular elements or in combination. It should be
understood that other material feed options may also be integrated
with the multi-element printer head as the current disclosure is
not limited to any particular number of material feed options.
[0242] In one specific example of a multi-element printer head,
material 1502 is a continuous copper wire fed through a central
channel. Further, material 1504 is a binding resin such as Nylon
plastic and material 1506 is a different binding resin such as a
dissolvable support material. The multi-element printer head 1500
is capable of extruding all the elements at once where, for
example, the copper wire 1502 might be surrounded by the nylon
binder 1504 on the bottom surface and the dissolvable support
material 1506 on the top surface, see section 1508. The
multi-element printer head 1500 may also deposit the copper wire
1502 coated with either the nylon binder 1504 or the soluble
support material 1506 separately, see sections 1510 and 1514.
Alternatively, the multi-element printer head 1500 can deposit the
above noted material options singly for any number of purposes, see
the bare copper wire at section 1512.
[0243] The ability to selectively deposit any of the one or more of
the materials in a given location as described above enables many
advanced functionalities for constructing parts using three
dimensional printing methods. Also, the ability to selectively
deposit these materials continuously also results in a
significantly faster deposition process. It should be understood
that while two specific resin materials and a core material have
been described above, any appropriate resin and core material might
be used and any number of different resins and cores might be
provided. For example, a single core and a single resin might be
used or a plurality of cores and a plurality of resins might be
provided in the multi-element printer head.
[0244] In a related embodiment, the multi-element printer head 1500
includes an air nozzle 1508 which enables pre-heating of the print
area and/or rapid cooling of the extruded material, see FIG. 33.
The inclusion of the air nozzle 1508 enables the formation of
structures such as flying leads, gap bridging, and other similar
features. For example, a conductive core material may be extruded
by the multi-element printer head 1500 with a co-extruded
insulating plastic, to form a trace in the printed part. The end of
the trace may then be terminated as a flying lead. To achieve this,
the multi-element printer head would lift, while commensurately
extruding the conductive core and insulating jacket. The
multi-element printer head may also optionally cool the insulating
jacket with the air nozzle 1508. The end of the wire could then be
printed as a "stripped wire" where the conductive core is extruded
without the insulating jacket. The cutting mechanism 8 may then
terminate the conductive core. Formation of a flying lead in the
above-noted manner may be used to eliminate a stripping step down
stream during assembly.
[0245] The above embodiments have been directed to three
dimensional printers that print successive filaments of continuous
core reinforced filament in addition to pure resins and their core
materials to create a three dimensional part. The position of
continuous cores or fibers can also be used with three dimensional
printing methods such as stereolithography and selective laser
sintering to provide three dimensional parts with core
reinforcements provided in selected locations and directions as
described in more detail below.
[0246] For the sake of clarity, the embodiment described below is
directed to a stereolithography process. However, it should be
understood that the concept of depositing a continuous core or
fiber prior to or during layer formation can be applied to any
number of different additive manufacturing processes where a matrix
in liquid or powder form to manufacture a composite material
including a matrix solidified around the core materials. For
example, the methods described below can also be applied to
Selective Laser Sintering which is directly analogous to
stereolithography but uses a powdered resin for the construction
medium as compared to a liquid resin. Further, any of the
continuous core filaments noted above with regards to the
continuous core reinforced filaments may be used. Therefore, the
continuous cores might be used for structural, electrical
conductivity, optical conductivity, and/or fluidic conductivity
properties.
[0247] In one embodiment, a stereolithography process is used to
form a three dimensional part. In stereolithography, the layer to
be printed is typically covered with resin that can be cured with
UV light, a laser of a specified wavelength, or other similar
methods. Regardless of the specific curing method, the light used
to cure the resin sweeps over the surface of the part to
selectively harden the resin and bond it to the previous underlying
layer. This process is repeated for multiple layers until a three
dimensional part is built up. However, in typical stereolithography
processes, directionally oriented reinforcing materials are not
used which leads to final parts with lower overall strength.
[0248] In order to provide increased strength as well as the
functionalities associated with different types of continuous core
filaments including both solid and multifilament materials, the
stereolithography process associated with the deposition of each
layer can be modified into a two-step process that enables
construction of composite components including continuous core
filaments in desired locations and directions. More specifically, a
continuous core or fiber may be deposited in a desired location and
direction within a layer to be printed. The deposited continuous
core filament may either be completely submerged in the resin, or
it may be partially submerged in the resin. After the continuous
fiber is deposited in the desired location and direction, the
adjoining resin is cured to harden around the fiber. This may
either be done as the continuous fiber is deposited, or it may be
done after the continuous fiber has been deposited as the current
disclosure is not limited in this fashion. In one embodiment, the
entire layer is printed with a single continuous fiber without the
need to cut the continuous fiber. In other embodiments, reinforcing
fibers may be provided in different sections of the printed layer
with different orientations. In order to facilitate depositing the
continuous fiber in multiple locations and directions, the
continuous fiber may be terminated using a simple cutting
mechanism, or other appropriate mechanism, similar to that
described above. In some applications, the same laser that is used
to harden the resin may be used to cut the continuous core
filament.
[0249] FIG. 34 depicts an embodiment of the steriolithography
process described above. As depicted in the figure, a part 1600 is
being built on a platen 1602 using stereolithography. The part 1600
is immersed in a liquid resin material 1604 contained in a tray
1606. The liquid resin material may be any appropriate
photopolymer. In addition to the resin bath, during formation of
the part 1600, the platen 1602 is moved to sequentially lower
positions corresponding to the thickness of a layer after the
formation of each layer to keep the part 1600 submerged in the
liquid resin material 1604. During the formation of each layer, a
continuous core filament 1608 is fed through a nozzle 1610 and
deposited onto the part 1600. The nozzle 1610 is controlled to
deposit the continuous core filament 1608 in a desired location as
well as a desired direction within the layer being formed.
Additionally, in some embodiments, the feed rate of the continuous
core filament 1608 is equal to the speed of the nozzle 1610 to
avoid disturbing the already deposited continuous core filaments.
In the depicted embodiment, as the continuous core filament 1608 is
deposited, a laser 1612, or other appropriate type of
electromagnetic radiation, is directed to cure the resin
surrounding the continuous core filament 1608 in a location 1614
behind the path of travel of the nozzle 1610. The distance between
the location 1614 and the nozzle 1610 may be selected to allow the
continuous core filament to be completely submerged within the
liquid resin prior to curing as well as to avoid possible
interference issues by directing the laser 1612 at a location to
close to the nozzle 1606. The laser is generated by a source 1616
and is directed by a controllable mirror 1618. The three
dimensional printer also includes a cutting mechanism 1620 to
enable the termination of the continuous core filament as noted
above.
[0250] In another embodiment of a stereolithography process, the
deposited continuous core filament is held in place by one or more
"tacks". These tacks correspond to a sufficient amount of hardened
resin material that holds the continuous core filament in position
while additional core material is deposited. The balance of the
material can then be cured such that the cross linking between
adjacent strands is maximized. Any number of different hardening
patterns might be used to provide desirable properties in the final
part. For example, when a sufficient number of strands has been
deposited onto a layer and tacked in place, the resin may be cured
in beads that are perpendicular to the direction of the deposited
strands of continuous core filament. Without wishing to be bound by
theory, curing the resin in a direction perpendicular to the
deposited strands may provide increased bonding between adjacent
strands to improve the part strength in a direction perpendicular
to the direction of the deposited strands of continuous core
filament. While a particular curing pattern is described, other
curing patterns are also possible as would be required for a
desired geometry and directional strength.
[0251] FIG. 35 depicts one embodiment of the stereolithography
process described above. As depicted in the figure, the continuous
core filament 1608 is tacked in place at multiple discrete points
1622 by the laser 1612 as the continuous core filament is deposited
by a nozzle, not depicted. After depositing a portion, or all, of
the continuous core filament 1608, the laser 1612 is directed along
a predetermined pattern to cure the liquid resin material 1604 and
form the current layer. Similar to the above system, the laser, or
other appropriate electromagnetic radiation, is generated by a
source 1616 and directed by a controllable mirror 1618. As
illustrated by the figure, the liquid resin material 1604 may be
cured in a pattern corresponding to lines 1624 oriented
perpendicular to the direction of the deposited strands of
continuous core filament 1608. Without wishing to be bound by
theory, since the cure front is perpendicular to the strands of
continuous core filament 1608, the crosslinking between the strands
is increased. It should be understood, that if separate portions of
the layer include strands of continuous core filament oriented in
different directions, the cure pattern may include lines that are
perpendicular to the direction of the strands of continuous fibers
core material in each portion of the layer. While a particular cure
pattern with lines that are oriented perpendicular to the
continuous fibers are described, other patterns are also possible
including cure patterns of lines that are oriented parallel to the
continuous fibers as the current disclosure is not limited to any
particular orientation of the cure pattern.
[0252] Similar to the three dimensional printing processes
described above with regards to depositing a continuous core
reinforced filament, it may be desirable to avoid the formation of
voids along the interface between the continuous core filament and
the resin matrix during the stereolithography process in order to
form a stronger final part. Consequently, it may be desirable to
facilitate wetting of the continuous core filament prior to curing
the liquid resin material. In some embodiments, wetting of the
continuous fiber may simply require a set amount of time. In such
an embodiment, the liquid resin material may be cured after a
sufficient amount of time has passed and may correspond to a
following distance of the laser behind the nozzle. In other
embodiments, the continuous core filament may be a continuous
multifilament core material. Such embodiment, it is desirable to
facilitate wicking of the liquid resin material between the
multiple filaments. Wetting of the continuous fiber and wicking of
the resin between the into the cross-section of the continuous
multifilament core may be facilitated by maintaining the liquid
resin material at an elevated temperature, using a wetting agent on
the continuous fiber, applying a vacuum to the system, or any other
appropriate method.
[0253] Having described several systems and methods for forming
parts using three dimensional printing processes, as well as the
materials used with these systems and methods, several specific
applications and components are described in more detail below.
[0254] In the simplest application, the currently described three
dimensional printing processes may be used to form parts using
composite materials with increased structural properties in desired
directions and locations as described above. In another embodiment,
optically or electrically conductive continuous cores may be used
to construct a part with inductors, capacitors, antennae,
transformers, heat syncs, VIA's, thermal VIA's, and a plurality of
other possible electrical and optical components formed directly in
the part. Parts may also be constructed with fluid conducting cores
to form fluid channels and heat exchangers as well as other
applicable fluidic devices and components.
[0255] In some embodiments, a part may also be constructed with
sensors, such as strain gauges, formed directly in the part to
enable structural testing and structural health monitoring. For
example, a cluster of printed copper core material can be added to
a layer to forming a strain gauge. Similarly, an optical fiber can
be selectively added to the part for structural monitoring reasons.
Optical fibers can also be printed in a loop to form the coil of a
fiber optic gyroscope with a plurality of possible advantages
including longer loop lengths for increased sensitivity as well as
component integration and simplified manufacturing. For example,
the optical coil of the gyro can be printed inside of the
associated external container, as part of a wing, or integrated
with any number of other parts. Additionally, an optical fiber
could be printed as part of a shaft encoder for an electrical
motor, which could also be formed using three dimensional
printing.
[0256] FIG. 36 illustrates a printed part incorporating many of the
components described above that are formed directly in the part
using the described three dimensional printing processes. The
printed part 1700 includes printed electrical traces 1702 for
connecting the printed electrical components as well as a printed
inductor 1704 and a printed antennae 1706 connected by the printed
electrical traces 1702. The printed part 1700 also includes a
printed fiber optic cable 1708. Additionally, depending on the
embodiment, the printed part 1700 may include contacts or leads,
not depicted, for connecting other components such as chip 1710 and
connectors 1712 to the printed part.
[0257] FIGS. 37-39 depict the printing and formation process for a
multilayer printed circuit board (PCB) using additive
manufacturing. As in subtractive PCB layout, a pattern of pads and
traces can be designed, and then printed, as illustrated in the
figures. However, the process of additive manufacturing of a PCB is
simple enough to perform on a bench using one machine, thereby
enabling a substantial acceleration of the design cycle.
[0258] FIG. 37 depicts printing of a multi-layer PCB 1800, on a
build platen 16. The PCB 1800 is formed with a conductive core
material 1802 and an insulating material 1804 which are deposited
using a printer head including a heated extrusion nozzle 10 and
cutting mechanism 8. Similar to the multielement printer head
described above, the conductive core material 1802 and insulating
material 1804 may be selectively deposited either individually or
together. Further, in some embodiments the conductive core material
1802 is solid to minimize the formation of voids in the deposited
composite material. When the conductive core material 1802 is
printed without the insulating material 1804 a void 1806 can be
formed to enable the subsequent formation of vias for use in
connecting multiple layers within the PCB 1800. Depending on the
desired application, the void 1806 may or may not be associated
with one or more traces made from the conductive core material
1802.
[0259] FIGS. 38 and 39 depict several representative ways in which
the currently described three dimensional printer could be used to
form various structures in a printed circuit board 1800. As above,
the printed circuit board 1800 can be printed with various
combinations of traces and voids. For example, voids 1812 are
associated with a single piece of the conductive core material 1802
which acts as a trace. The voids 1812 are subsequently filled with
solder or solder paste to form solder pads 1814. In a similar
fashion, the void 1816 is associated with two traces and can also
be filled with solder or solder paste to form an electrically
connected via 1818 between two or more printed layers. As an
alternative to the above, a void 1820 may not be associated with a
trace. Such a void may also be filled with solder or solder paste
to function as a thermal via 1822. While the solder and/or solder
paste may be applied separately, in one embodiment, the solder fill
can be done using an optional print head 1810 which is used to
dispense solder or an equivalent electrical binding agent 1808. The
solder may be applied as a molten solder, or as a solder paste for
post processing thermal curing using any appropriate technique. The
ability to print various components and traces within a circuit
board coupled with the ability to apply solder and/or solder paste,
may help to further accelerate the prototyping process of a printed
circuit board. In addition to the above, separate components may be
placed on the printed circuit board by the same machine, another
machine, or manually. Subsequently, the printed circuit board can
be heated to bond the separate components to the printed circuit
board and finish the part. It should be understood that while
manufacturing processes for a printed circuit board described
above, the ability to selectively form various structures within a
three dimensional printed component can be used for any number of
different applications.
[0260] The presently described three dimensional printing systems
and methods may also be used to form composite structures. A
schematic representation of a composite structure is depicted in
FIG. 41A which shows a sandwich panel composite part. The top
section 1900, and bottom section 1902, are printed using a
continuous core reinforced filament to form relatively solid
portions. In contrast, the middle section 1904 may be printed such
that it has different properties than the top section 1900 and the
bottom section 1902. For example the middle section 1904 may
include multiple layers printed in a honeycomb pattern using a
continuous core reinforced filament, a pure resin, or even a three
dimensionally printed foaming material. This enables the production
of a composite part including a lower density core using a three
dimensional printer. Other composite structures that are not easily
manufactured using typical three dimensional printing processes may
also be manufactured using the currently described systems,
materials, and methods.
[0261] While several different types of applications are described
above, it should be understood that the three dimensional printing
systems and materials described herein may be used to manufacture
any number of different structures and/or components. For example,
the three-dimensional printing systems and materials described
herein may be used to manufacture airplane components, car parts,
sports equipment, consumer electronics, medical devices, and any
other appropriate component or structure as the disclosure is not
limited in this fashion
[0262] In addition to using the continuous core reinforced
filaments to form various composite structures with properties in
desired directions using the fiber orientation, in some embodiments
it is desirable to provide additional strength in directions other
than the fiber direction. For example, the continuous core
reinforced filaments might include additional composite materials
to enhance the overall strength of the material or a strength of
the material in a direction other than the direction of the fiber
core. For example, FIG. 41B shows a scanning electron microscope
image of a carbon fiber core material 2000 that includes
substantially perpendicularly loaded carbon nanotubes 2002. Without
wishing to be bound by theory, loading substantially perpendicular
small fiber members on the core increases the shear strength of the
composite, and advantageously increases the strength of the
resulting part in a direction substantially perpendicular to the
fiber direction. Such an embodiment may help to reduce the
propensity of a part to delaminate along a given layer.
[0263] In traditional composites, fibers are laid up, then a hole
is drilled after the fact (subtractive machining). This is
illustrated in FIG. 40A which illustrates multiple layers 1850,
which may either be formed using pure polymer filaments or core
reinforced filaments. As also depicted in the figure, a hole 1852
is subsequently formed in the part using a drilling or other
appropriate machining process. In contrast, in some embodiments, a
core reinforced filament 1854 is used to form a hole directly in a
part, see FIGS. 40B and 40C. More specifically, the core reinforced
filament 1854 comes up to the hole, runs around it, then exits from
the direction it came, though embodiments in which the filament
exits in another direction are also contemplated. A benefit
associated with this formation method is that the hole is
reinforced in the hoop direction by the core in the core reinforced
filament. As illustrated in FIG. 40B, the core reinforced filament
1854 enters the circular pattern tangentially. This is good for
screws that will be torqued in. In another version, the core
reinforced filament 1854 enter the circular pattern at the center
of the circle. Of course, it should be understood that other points
of entering the pattern are also possible. In one embodiment, the
entrance angle is staggered in each successive layer (also
described in a PPA). For example, if there are two layers, the
entering angle of the first layer may be at O degrees while the
entering angle for the second layer may be at 180 degrees. This
prevents the buildup of a seam in the part. If there are 10 layers,
the entering angle may be every 36 degrees or any other desired
pattern or arrangement.
[0264] As noted above, typical towpregs include voids, this may be
due to considerations such as at a temperature and rate at which a
green towpregs pass through a nozzle as well as the difference in
areas of the green and impregnated towpregs. Due to the relatively
high-viscosity of thermoplastics, for example, sections of the
extruded material also typically are not fully wetted out. These
"dry" weak points may lead to premature, and often catastrophic,
component failure.
[0265] In view of the above, it is desirable to improve the wetting
or impregnating of towpregs during the impregnation step. One way
in which to do this is to pass a material including a core of one
or more fibers and a matrix material through a circuitous path
involving multiple changes in direction of the material while the
matrix material is maintained in a softened or fluid state. For
example, in the case of a polymer matrix, the polymer may be
maintained at an appropriate temperature to act as a polymer melt
while the circuitous path functions to mechanically work the matrix
material into the fibers. This process may help to reduce the
processing time while enhancing the fiber wet-out to provide a
substantially void free material. Moreover, reducing the residence
time of the matrix material, such as a thermoplastic matrix
material, at high temperature reduces degradation of the material
which results in further strengthening of a resultant part formed
using the composite material. The above noted process may be used
for both continuous, and semi-continuous, core materials.
[0266] In some embodiments, a circuitous path used to form a
desired material is part of a standalone system used to manufacture
a consumable material. Alternatively, in other embodiments, a
circuitous path is integrated in the compression stage of a print
head. In such an embodiment, friction within the print head may be
minimized by using one or more smooth walled guide tube with a
polished surface. Further, the one or more guide tubes may be
close-fitting relative to the material, such that the compressed
fiber does not buckle and jam the print head.
[0267] FIG. 42 depicts one possible embodiment of a
three-dimensional printer head 2102 including a circuitous path
impregnation system. In the depicted embodiment, a continuous core
filament 2100 is driven by a feed mechanism 2110 (e.g. the depicted
rollers), into a cutting mechanism 2104, through a receiving
section 2106, and into a heated zone 2112 of the nozzle. When
passing through the heated zone 2112, the continuous core filament
2100 passes through a circuitous path 2108 corresponding to a
channel that undergoes at least a first bend in a first direction
and a second bend in a second direction prior to the material being
extruded from the nozzle into one or more layers 2116 on a print
bed 2118. The resulting shape of the circuitous path forms a
somewhat sinusoidal path. However, it should be understood that any
number of bends and any desired curvature might be used to form the
circuitous path. Similar to the above noted printer heads, the
printing process may be controlled using a controller 2114 which
may also control the impregnation processes. The advantages
associated with the depicted embodiment is provided by the back and
forth mechanical motion of the continuous core filament 2100 within
the circuitous path 4 which aids in the impregnation of the input
material.
[0268] FIG. 43A illustrates one possible embodiment of the
continuous core filament 2100 when it is input to the system. As
illustrated in the figure, the continuous core filament 2100
corresponds to a commingled green towpreg including one or more
fibers 2120 bundled with a matrix material 2122 in the form of
fibers or particles. After passing through the heated zone and the
circuitous path, the continuous core filament 2100 has been fully
wetted by the matrix material 2122 to provide a substantially void
free continuous core filament, see FIG. 43B.
[0269] In another embodiment, the circuitous path is provided by
offset rollers which may either be stationary, or they may be
constructed to advantageously open during initial threading to
provide a straight through path and subsequently close to provide
the desired circuitous path. FIGS. 44A and 44B show one possible
implementation of such an embodiment. As depicted in the figures,
three or more rollers 204 are placed within the printer head 2102
to provide the desired circuitous path. During use, the continuous
core filament 2100 is fed through the offset rollers by the feeding
mechanism 2110 and through the printer head. FIG. 44B depicts an
optional loading strategy. In such an embodiment, the rollers 2124
are selectively movable between a first position in which they form
a circuitous path as illustrated in FIG. 44A and a second position
in which they do not obstruct a path between an inlet and outlet of
the printer head 2102 in order to facilitate threading of the
system with the continuous core filament 2100, see FIG. 44B. After
the material has threaded past the rollers 2124, they may return to
the first position to form the circuitous path depicted in FIG.
44A.
[0270] In another embodiment, not depicted, a circuitous path
located within a print head is formed by a flexible tube such as a
polytetrafluoroethylene tube. The flexible tube is selectively
placed in a straight configuration to permit threading of the
printer head. Subsequently, the flexible tube is deformed into a
circuitous path after threading has been completed to facilitate
impregnation of a continuous core filament passing there through as
described above.
[0271] In some instances, it is desirable to provide a fully wetted
or impregnated material to the feeding mechanism of a printer head.
In such an embodiment, a circuitous path wet-out of a continuous
core filament 2100 is performed as a pre-treatment step within the
tension side of a three-dimensional printer, prior to feeding the
resulting substantially void material into the compressive side of
the three-dimensional printer, see FIG. 45. As depicted in the
figure the continuous core filament 2100 enters a pre-conditioner
2124. As noted above, when entering the pre-conditioner 124, the
continuous core filament 2100 may correspond to a comingled towpreg
including one or more fibers and matrix material. As the continuous
core filament 2100 passes through the pre-conditioner 2124, it is
heated and passes through a circuitous path which may be provided
by a set of offset rollers 2126, or other appropriate configuration
to facilitate impregnation of the material. After passing through
the pre-conditioner 2124, the continuous core filament 2100 passes
through the feeding mechanism 2110 corresponding to a set of drive
rollers. The feeding mechanism 2110 feeds the continuous core
filament 2100 into a print head 2130 including a vacuum pressure
system 2132. The vacuum pressure system 2132, or other appropriate
system, varies a pressure applied to the continuous core filament
2100 within the print head. Without wishing to be bound by theory,
these pressure variations may facilitate impregnation of the fibers
and burst air pockets within the towpreg. In another preferred
embodiment, a continuous vacuum line is used for the vacuum
pressure system 2032 instead of the oscillating pump as depicted in
the figure. Additionally, while a vacuum may be applied to vary a
pressure within the print head, embodiments in which positive
pressures are applied to the print head are also contemplated.
[0272] In yet another embodiment, the matrix material contained
within a green continuous core filament is worked into the fibers
by passing through one or more compressive roller sets while the
matrix is hot and capable of flowing. FIG. 46 shows one embodiment
of a three-dimensional print head 2034 including a first and second
set of compression rollers 2136 disposed within the print head. As
depicted in the figure, the continuous core filament 2100 passes
through the print head where it is heated and subjected to two
subsequent compressions from the two sets of compression rollers.
While two sets of rollers are depicted in the figures, additional
rollers within the print head may also be used.
[0273] In another embodiment, oscillating pressures and/or vacuums
are used to work the matrix material into the fiber core of a
continuous core filament. Without wishing to be bound by theory,
applying reduced pressures, or increased vacuums, to the material
removes voids. Conversely, applying increased pressures, or
decreased vacuums, then forces the resin deeper into the fiber
towpreg as the air pressure around said towpreg increases. The
above noted process may either be performed completely with
vacuums, positive pressures, or a combination of the two as the
disclosure is not so limited. For example, a material might be
cycled between ambient pressure and a high pressure, between
ambient pressure and a vacuum, or between positive pressures and
vacuums.
[0274] In the above embodiments, mechanically working the matrix
into the fiber cores enables the production of substantially void
free towpregs from a variety of starting materials. For example,
comingled towpregs can be used. In an additional embodiment, a flat
towpreg in which the polymer matrix is only partially wicked into
the underlying fibers is subjected to the circuitous path wetting
method described above to wet out the towpreg. In addition to
enabling the manufacture of various types of towpregs, if used as a
pre-treatment, a precision extrusion die can be used to form the
impregnated material into a desired size and shape for extrusion
from a three dimensional printer. For example, the material may
have a circular cross section though any other appropriately shaped
cross section might also be used.
[0275] When desirable, a precision roller set can be used to
maintain a constant thickness along a relatively wider width of
material output from a print head 2102. Such an embodiment may be
of use when dealing with wider materials such as flat towpregs.
FIG. 47 shows a print head 2102 translating in a first direction. A
nozzle 2136 of the print head is attached to a trailing compression
roller 2138. The roller imparts a compressive force to the material
deposited on to the onto print bed 2140. Depending on the
embodiment, the trailing roller 2138 can articulate around the Z
axis using any number of different mechanisms. For example, in one
embodiment, the print head 2102 is free-rotating on a bearing, such
that the roller always trails the direction of travel of the print
head. In another embodiment, the entire print head 402 is
constructed to rotate. Alternatively, the print bed 2140 may be
rotated to achieve the desired trailing and displacement.
[0276] FIG. 48 shows one embodiment of a high-speed continuous core
printer capable of using the above described materials. In the
depicted embodiment, the printer includes a print arm 2200
including a plurality of nozzles. The nozzles include a pure resin
nozzle 2202 adapted to print pure resin 2208. The print arm 2200
also includes a continuous core filament nozzle 2204 adapted to
print a continuous core filament 2210 for use in fine detail work.
Additionally, the print arm 2200 includes a tape dispensing head
2206 capable of printing one or more printable tapes 2212. The tape
dispensing head enables large infill sections to be printed quickly
using the noted printable tapes. However, fine detail work and gaps
that cannot be filled in by the tape can be filled by either the
pure resin nozzle 2202 or continuous core filament nozzle 2204 as
the disclosure is not so limited. The above noted method and system
using wide tape fills greatly improves the speed of a printer,
enabling higher throughput, and commensurately lower cost.
[0277] As noted above, in some embodiments, it is desirable to
provide a material with a smooth outer surface for a variety of
reasons. As detailed below, the smooth outer surface, a desired
shape, and/or a desired size may be obtained in a variety of
ways.
[0278] In one embodiment, a core reinforced filament includes an
internal portion including axially aligned continuous or
semi-continuous fibers, or other materials, in the form of a tow,
bundle, yarn, string, rope, thread, twine, or other appropriate
form. The internal portion also includes a matrix in which the
fibers are embedded. The core reinforced filament also includes an
external coating disposed on the internal portion of the filament.
The external coating may be shaped and sized to provide a desired
cross-sectional shape and size. The resulting core reinforced
filament may be used in a three dimensional printing process as
described herein as well as other appropriate three dimensional
printing processes as the disclosure is not so limited.
[0279] In a related embodiment, a method for manufacturing a core
reinforced filament includes embedding a tow, bundle, yarn, string,
rope, thread, cord or twine in a polymer matrix using any
appropriate method. The resulting filament is subsequently extruded
with a polymer to form the external coating noted above. As
described in more detail below, the external coating may be made
from the same material, or a different material, as the matrix
material of the internal portion of the filament.
[0280] FIG. 49A depicts a process to make a fully-wetted or
impregnated core reinforced filament with a smooth outer coating
for use in a three-dimensional printing system. As depicted in the
figure, a continuous core element 2300 is pulled into a
co-extrusion die 2302. In some embodiments, the continuous core
element 2300 is subjected to various pretreatments at 2301 prior to
entering the co-extrusion die 2302 as described in more detail
below. Once introduced into the co-extrusion die 2302 the
continuous core element 2300 is impregnated with matrix material
2306 at a mixing point 2304. Either during, or prior to wetting or
impregnation of the continuous core element with the polymer, an
optional vacuum step may be employed to remove entrapped air from
the continuous core filament. FIGS. 49B and 49C depict cross
sectional views of various starting continuous core elements 2300
which may be towpregs including a plurality of aligned reinforcing
fibers. As complete wetting or impregnating is the primary goal of
this step (as opposed to merely coating in traditional co-extrusion
dies), the temperature and pressure of the mixing step may be
increased to achieve the desired full-wetting/impregnating through
the fiber bundle. Alternatively, or in addition to the above, a
circuitous path and/or varying pressure may be applied as described
above to further facilitate wetting/impregnation of the
material.
[0281] As many carbon fiber and fiberglass towpregs are initially
in a tape-like format, the die exit 2308 of the co-extrusion die
may act to consolidate the continuous core element and polymer
matrix material into a desired shape and size to provide a smooth,
constant diameter, composite filament. However, the filament will
start to distort down-stream of the coextrusion die as occurs with
typical filament manufacturing processes. The inventors have
recognized that this distortion is an artifact of cooling the
extrusion without support which is somewhat akin to ejecting an
injection molded part too soon which then warps when outside of the
mold. Consequently, in some embodiments, a cooling tube 2312 and
operatively coupled cooling element 2310, such as a cooling jacket,
are aligned with and support the extruded material. Consequently,
the extruded core reinforced filament is permitted to cool while
being constrained to a desired size and shape. Lubricating agents
may advantageously be applied to the filament upon entry to the
tube, or at points along a length of the tube. The lubricating
agents may either evaporate, or be washed off at the later time.
The lubricants may function to reduce the dragging friction of the
core reinforced filament within the tube to substantially prevent,
or at least reduce, "skipping" or surface roughness from dragging
the filament through the cooling tube during cooling. Depending on
the core material, and its corresponding compressibility and
ductility, the cooling tube may be built with a series of different
inner diameter "dies" to achieve a desired shape and size.
Alternatively, a plurality of discrete "cooling dies" might be used
in place of a cooling tube for certain materials. An output core
reinforced material 2314 may exhibit cross sections similar to
those depicted in FIGS. 49E-49F. Depending on the amount of
compression used in the cooling tube, or die, the material may
exhibit varying cross sectional profiles that conform either more
or less to a shape of the tube or die.
[0282] In some embodiments, the core reinforced filament is fed
into a second co-extrusion die 2316 where it is coated with another
matrix material 2318, such as a polymer or resin, prior to being
output through the die exit 2320 as a coated core reinforced
filament 2322. This outer coating 2326 is disposed on the internal
portion 2324. The outer coating 2326 may be made from the same
material, or a different material, as the matrix material 2306 in
the internal portion. Therefore, the outer coating 2326 may be
selected to provide a desired performance characteristics such as
bonding to previously deposited layers, wear resistance, or any
other number of desired properties. Additionally, in some
embodiments, the outer coating 2326 provides a smooth, fiber-free
outer diameter as shown in the cross-section is presented in FIGS.
49G-491. FIG. 49G presents an embodiment of the core reinforced
filament including an internal portion 2324 and an outer coating
2326 formed with different matrix materials as well as a plurality
of filaments forming the continuous core. FIG. 49H depicts an
embodiment of the core reinforced filament including an internal
portion 2324 and an outer coating 2326 formed with the same matrix
material as well as a plurality of filaments forming the continuous
core. FIG. 49I presents an embodiment of the core reinforced
filament including an internal portion 2324 including a solid
continuous core 2300. The inner and outer matrix materials may be
any appropriate binder used in composites, including, but not
limited to, thermoplastics, thermosets, resins, epoxies, ceramics,
metals, waxes, and the like.
[0283] FIG. 50A depicts an alternative roller-based method to
achieve full-wetting/impregnation of the fiber, combined with an
outer coating. Similar to the above, the core material 2300 may
have a cross-sections as depicted in FIGS. 50B and 50C.
Additionally, the core material 2300 may be subjected to an
optional pre-treatment step at 2301. The core material 2300 is
passed through a set of dispersion rollers 2330 which are
constructed and arranged to flatten the cross-section of the core
material to a flattened cross-sectional shape 2332 illustrated in
FIG. 50D. Without wishing to be bound by theory, dispersing the
individual fibers of the continuous core into a flattened shape may
help to facilitate wetting/impregnation of the matrix material 2306
when it is introduced to the flattened continuous core element 2332
at the mixing point 2304. Similar to the above, the continuous core
element and matrix material may be subjected to a circuitous path
and/or varying pressures to further facilitate impregnation of the
matrix material. Additionally, in the depicted embodiment, the
system may optionally include a set of rollers 2334 located
downstream from the mixing point 2304. The rollers 2334 may apply a
force to the composite filament to further force the matrix
material 2306 into the continuous core element 2300. A
cross-section of the resulting composite flattened tape 2336 is
illustrated in FIG. 50E. The resultant flattened composite tape
2336 is subsequently fed into a forming die 2338. This step can
either be achieved with a heated forming die, that is heated to a
sufficient temperature in order to reflow the material, or the
forming die 2338 is located sufficiently close to the exit of the
rollers 2334 such that the composite flattened tape is at a
sufficient temperature to be formed when entering the die. Again,
similar to the above, an optional cooling tube 2312 and an
associated cooling element 2310 may be associated with the forming
die 2338 in order to support a cross-section of the core reinforced
filament 2314 as it cools, see FIGS. 50F-50G. An outer coating may
then be applied to the court reinforced filament to forming a
coated core reinforced filament 2322 as described above.
[0284] While the above described embodiments have been directed to
the use of a fully wetted, fully wicked material, that is
substantially void free, it should be noted that described outer
coatings and impregnation methods may be used with materials
including voids as well. Additionally, green materials that have
not been wetted might also be used with the three dimensional
printers described herein. Further, while various shapes such as
flattened tapes and rounded cross-sectional profiles are described
above with regards to the manufacturing processes, any appropriate
shape of the material and/or resulting core reinforced filament is
possible as the disclosure is not so limited.
[0285] The composition of the aforementioned two polymer matrix
binders used in the internal portion and outer coating of a
composite filament may differ by one or more of the following
factors: polymer molecular weight, polymer weight distribution,
degree of branching, chemical structure of the polymer chain and
polymer processing additives, such as plasticizers, melt viscosity
modifiers, UV stabilizers, thermal stabilizers, optical
brighteners, colorants, pigments or fillers. Manufacturing of core
reinforced filaments with two different binder compositions may be
practiced in several different ways depending on which particular
processing characteristic or the property of the finished part one
desires to modify or control.
[0286] In one embodiment, it is desirable to preserve the uniform
distribution of the fibers in the interior portion of the filament
and the circular cross section shape. In such an embodiment, the
polymer matrix of the interior portion may exhibit a higher melting
point than the melting point of the polymer matrix in the outer
coating. Consequently, the interior portion of the filament remains
in a solid, or at least a semi-solid highly viscous state, when the
external coating is applied. Correspondingly, the fibers contained
within the continuous core will stay in place and the filament will
retain its circular cross-sectional shape during application of the
outer coating polymer matrix by co-extrusion while avoiding
migration of the continuous fibers through the molten matrix of the
interior portion of the filament to the outer coating of the
filament during the co-extrusion step.
[0287] In another embodiment, it is desirable to improve
impregnation/wetting of the fiber towpreg by the matrix binder.
Consequently, in some embodiments, a less viscous polymer melt is
used as the matrix material in the interior portion of the
filament. Preferably, the polymer matrix material used for the
interior portion of the filament should have not only low
viscosity, but also exhibit improved interfacial wetting of the
fiber surface. Without wishing to be bound by theory, this may be
obtained by matching the surface energy of the imbibing polymer
melt with the surface energy of the continuous fiber material. The
polymer matrix material used for the external coating may comprise
a polymer with a higher melt viscosity than the interior matrix
polymer. The exterior polymer matrix material may also exhibit a
lower melting point than the interior polymer. The wetting
properties of the outer coating matrix towards the continuous core
is of lesser importance as the two should not in principle be in
direct contact.
[0288] In yet another embodiment, is desirable to facilitate the
adhesion of an external coating to the underlying bundle through
the modification of the surface energy of the polymer melt and the
continuous core filaments. The surface energy can be controlled by
a number of methods, including, but not limited to, varying the
content and the type of the polar groups in the polymer backbone,
the addition of surface active components to the melt, for example,
surfactants, oils, inorganic fillers etc., exposing the fibers to
electric gas discharge plasmas, chemical vapor deposition, ozone,
or reactions with, or coating of, surface modifying compounds from
solutions.
[0289] In another embodiment, surface energy modifiers may also be
used to strengthen the interlayer bonding of the filament as it is
deposited by a three dimensional printer. For example, ozone may be
deposited by the print head to promote adhesion of a new layer to
an existing layer. In another embodiment, the build chamber may be
filled with a sufficient proportion of ozone to activate the
exposed surfaces.
[0290] In yet another embodiment of the present invention, it may
be advantageous to improve the bond strength of freshly extruded
fiber-rich filament to the underlying layer by selectively applying
a stream of heated vapor to a small area adjacent to, and/or just
ahead of, the deposition point of the freshly deposited
filament.
[0291] In another embodiment, it is contemplated that the bond
strength between the freshly extruded fiber-rich filament and the
underlying layer may be improved by selectively directing a stream
of air or another gas consisting of a sufficient concentration of
ozone toward a small area adjacent to, and just ahead of, the
deposition point of the freshly deposited filament surface. Ozone
readily reacts with the atomically thick surface layers of organic
polymers to create a multitude of polar reactive surface groups,
such as hydroxyl, ozonide, peroxide, hydroperoxide, aldehyde and
carboxylic groups, which by their very reactive chemical and/or
polar nature facilitate bonding of the surface layer to another
material, such as ink, adhesive or another polymer binder.
[0292] In yet another embodiment, it is desirable to increase the
bonding strength with a build platform to help prevent lifting off
of a part, or section of a part, from the build platform.
Consequently, in some embodiments, a surface energy modifier is
applied to the build platform to facilitate the adhesion of the
extruded filament to said platform. In some embodiments, the noted
adhesion modification is used to increase the adhesion of the first
bonding layer to the build platform in a few key areas, such as the
corners of a box, thereby causing greater adhesion where the part
is most likely to peel up from the platform. The center of the box,
however, may be substantially free of surface energy modifiers to
facilitate easy removal.
[0293] With regards to the above noted embodiments, it should be
understood that the timing and/or quantity of deposited ozone,
vapor, or other surface energy modifier may be varied to obtain a
desired level of adhesion.
[0294] In another embodiment, a magnetic filler is loaded into the
matrix material. The magnetic filler may either be magnetically
active, like iron or steel, or it may be magnetized as the
disclosure is not so limited. In the case of continuous core
printing of electronics, the magnetic filler could be used to form
a three dimensionally printed actuation members. Additionally, the
magnetic matrix particles could be used to magnetically stick a
part to a printing table during printing, and then release at the
conclusion of printing. The magnetic material may either be
integrated into a final part, or it may advantageously be
integrated into a removable support material with similar matrix
exhibiting properties similar to the remainder of the material.
[0295] In yet another embodiment, the magnetically active filler
particles enable measurement and detection of the material, or
support structure, using x-rays or metallic sensors. For example,
using a material including metallic powder in the support material,
and not the model material, would enable easy detection of the
removal of all the support material. In another embodiment, the
magnetic material is added to a part, or all, of a part, to enable
the detection of intricate features in x-ray detection, that would
otherwise be invisible.
[0296] In some embodiments, a continuous core, such as continuous
carbon fibers, is combined with a semi-aromatic polyamides and/or a
semi-aromatic polyamide blends with linear polyamides which exhibit
excellent wetting and adhesion properties to the noted continuous
carbon fibers. Examples of such semi-aromatic polyamides include
blends of semi-aromatic and linear polyamides from EMS-Grivory,
Domat/Ems, Switzerland, such as Grivory HT1, Grivory HT2, Grivory
HT3 and other similar blends. By combining continuous reinforced
fiber towpregs with high-temperature melting and fiber wetting
polyamides and their blends, parts may be manufactured which are
characterized by exceptional mechanical strength and long-term
temperature stability at use temperatures 120.degree. C. and higher
while ensuring extrudability of the composite tow, excellent
fiber-matrix wettability, complete fiber towpreg permeation with
the resin and excellent shear strength at the fiber-matrix
interface.
[0297] The optional pre-treatments noted above are intended to
facilitate full wetting of the core material, and wicking of the
matrix material into the centers thereof. Various types of
pretreatments can include categories such as mechanical, rheology,
and fiber-wetting pretreatments. The particular method(s) employed
will depend on the matrix material chosen, and the core
selected.
[0298] Appropriate mechanical pretreatments include, spreading the
individual fibers of the core into a flattened ribbon-shaped
towpreg by mechanical or pneumatic means before contacting with the
resin or melt (i.e. dip coating). Alternatively, a towpreg may pass
through a melt in a chamber that is periodically evacuated to
expand and remove air bubbles trapped between the fibers and to
force the resin or melt into the interstitial space between the
fibers when the vacuum is released. Additionally, periodic cycles
of higher air pressure may improve the effectiveness of the process
by changing the size of entrapped air bubbles and forcing the
renewal of the air-fiber interface, thus, facilitating bubble
migration. Additionally, a resin or polymer milk may be injected
from one side of a continuous core such that it is injected through
the continuous core as compared to simply surrounding it during a
traditional coextrusion process. Should be understood that other
mechanical pretreatments are also possible.
[0299] Appropriate rheological pretreatments of a continuous core
include the use of a low viscosity or high melt flow index resins
or polymer melts. Additionally, polymers exhibiting low molecular
weights and/or linear chains may be used. Polymers exhibiting a
sharp melting point transition with a large change in viscosity
might also be used. Such a transition is a typical property
exhibited by polyamides. Various features such as multiple port
melt injection, angled channels, as well as fluted or spiral-groove
extrusion channel surface "morphologies" may be used to induce
higher melt turbulence and non-laminar melt flow which may result
in enhanced impregnation of the matrix material. Melt viscosity
modifiers and lubricants used to lower the effective melt viscosity
and improve slip at the fiber surface might also be used.
[0300] Appropriate fiber wetting pretreatments may include
precluding the fiber surfaces with a very thin layer of the same or
similar polymer from a dilute polymer solution followed by solvent
evaporation to obtain a like-to-like interaction between the melt
and the fiber surface. Polymer or resin solutions in neutral and
compatible solvents can have concentrations from about 0.1 wt.-% to
1 wt.-% or higher. Additionally, one or more surface activation
methods may be used to introduce or change the polarity of the
fiber surface and/or to introduce chemically reactive surface
groups that would affect wetting/impregnation (contact angle) and
adhesion (matrix-fiber interfacial shear strength) by physically or
chemically bonding the polymer matrix with the fiber surface.
Several examples of suitable surface activation methods include,
but are not limited to: atmospheric pressure smface oxidation in
air; air enriched in oxygen, nitrogen oxides, or other reactive
gases, such as halogenated, sulfur, silicon or other volatile
compounds: as well as a high-voltage corona discharges (a method
widely used in activating polyolefin film surfaces for printing).
Low-pressure plasma activation techniques in air, oxygen, or the
other gases enumerated above may also be used to introduce reactive
chemical surface groups with a chemical character defined by the
process conditions (time, pressure, discharge energy (electrode
bias voltage), residence time and the composition of the reactive
gas. The fiber surface may also be chemically activated using:
activation methods in gas and liquid phase, such as silanization in
the presence of hexamethyldisilizane (HMDS) vapors, especially at
elevated temperatures: and solvent-phase surface modification using
organosilicon or organotitanium adhesion promoters, such as
tris(ethoxy)-3-aminopropylsilane, tris(ethoxy) glycidyl silane,
tetraalkoxytitanates and the like.
[0301] While the present teachings have been described in
conjunction with various embodiments and examples, it is not
intended that the present teachings be limited to such embodiments
or examples. On the contrary, the present teachings encompass
various alternatives, modifications, and equivalents, as will be
appreciated by those of skill in the art. Accordingly, the
foregoing description and drawings are by way of example only.
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