ABSTRACT
Abstract
A print head comprising two shafts disposed in opposite sides of a filament to drive the filament to a heated chamber for delivering a molten material. The shafts are actively driven, for example, by two independent motors. The two shaft configuration of the print head can improve a control of the filament movement rate, especially for soft filament materials.
Description
The present application is a continuation of application Ser. No. 15/464,348, filed on Mar. 21, 2017, U.S. Pat. No. 10,926,527, issued on Feb. 23, 2021, entitled â3D printer systems and methodsâ, which claims priority from U.S. Provisional Patent Application Ser. No. 62/310,816, filed on Mar. 21, 2016, entitled: â3D printer systems and methodsâ, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
3D printers can be used to build solid objects by printing layers by layers of building materials. The building materials can be in liquid or semi liquid form at the 3D printer head, for example, a solid material can be heated and then extruded from a 3D printer nozzle. The layers of building materials can be solidified on a substrate.
3D printer systems can use a fused filament fabrication (FFF) process (sometimes called fused deposition modeling (FDM) process) in which a filament is moved, e.g., by a filament moving mechanism, toward a heated zone. The filament can be melted, and extruded on a platform to form a 3D object. The melted filament can adhere to the walls of the heated printer head, resulting in a deformed printed lines.
It would therefore be advantageous to have advanced 3D printing systems and methods that have improved printing mechanisms.
SUMMARY OF THE DESCRIPTION
In some embodiments, the present invention discloses a print head for a 3D printer for printing a structure using a filament. The print head can include two hobbed shafts disposed in opposite sides of the filament and contacting the filament. The shafts can be configured to rotate in opposite directions for driving the filament, for example to a heated chamber. The heated chamber can be configured to heat the filament to a melting temperature, so that the print head can deliver a molten material.
In some embodiments, one shaft of the two shafts can be coupled to a motor, e.g., to be actively driven by the motor. The other shaft can be coupled to the one shaft by a coupling mechanism, such as by a gear set or by a belt.
In some embodiments, each shaft can be coupled to one motor, e.g., two shafts can be coupled to two independent motors. The motors can be independent, e.g., the filament can be actively driven by the two independent motors. The motors can be driven at a same speed or at different speeds, for example, to ensure an appropriate delivering of material to the heated chamber.
In some embodiments, an assembly, such as a spring assembly, can be coupled to the print head to adjust the distance between the two shafts. The adjustment can be used to change a friction with the filament, e.g., a driving force to the filament. For example, a soft filament might need a smaller distance to ensure an appropriate force to the filament to drive the filament.
The print head can be coupled to a 3D printer, such as movably coupled, e.g., the print head can be securely coupled to the 3D printer and can be removed from the 3D printer.
In some embodiments, the print head can include a conduit having a channel for guiding the filament. The diameter of the channel can be about the size of the filament, so that the filament can easily move within the channel. Further, the conduit can include a low friction material, such as Teflon, which can assist in the movements of the filament.
The print head can include two motors with each motor having a shaft. The motors are configured to drive the filament along the channel by contact, e.g., the motor shafts can be in contact with the filament, so that the motors turn, the friction with the filament can drive the filament. The contact can be a direct contact, e.g., the motor shafts can directly contact the filament. To increase a friction force, a portion of the surface of the shafts can be hobbed, e.g., roughened. The hobbed surfaces can then contact the filament for driving the filament.
The contact can be an indirect contact, e.g., the motor shafts can contact the filament through an element fixedly coupled to the shafts. For example, a gear or a disc with an irregular circumference surface can be coupled to a shaft. The teeth of the gear of the irregular surface can increase a friction while in contact with the filament. The high friction can assist in moving the filament along the guiding channel.
In some embodiments, the conduit can include two cut portions for accepting the two shafts or the gears (e.g., a gear or a disc) fixedly coupled to the shafts. The cut portions can be at two opposite side of the conduit, cut through the conduit until reaching the channel. Each cut portion can expose a portion of the channel. A shaft can pass through the cut portion, with a portion of the shaft surface, e.g., the hobbed surface, contacting the filament through the corresponded exposed portion. Alternatively, a shaft can pass through the cut portion, with a gear surface contacting the filament through the corresponded exposed portion. With the conduit having the cut portions, the filament is constrained in the intended path, e.g., along the channel direction. The conduit can ease the insertion of the filament to the print head, since the filament just need to enter the conduit. Subsequent movements of the filament can be guided by the conduit. The conduit can also prevent the accumulation of filament in the area under the shafts, especially if the downstream of the filament path is blocked. Essentially, the conduit almost completely covers the filament, e.g., the cut portions can expose sections of the filament, but the exposed sections are blocked by the shafts or the gears.
In some embodiments, the shafts can be disposed in parallel with each other and perpendicular to the conduit. The shafts can be configured to be in opposite sides of the filament and contacting the filament. The motors can be disposed in opposite directions with respect to the conduit. The shafts can be configured to rotate in opposite directions for driving the filament along the channel.
In some embodiments, an assembly can be coupled to one shaft or one motor or one motor mount, for example, for pushing the one shaft to the other shaft, e.g. for adjusting a distance between the two shafts. The assembly can be spring loaded.
In some embodiments, the motors can be coupled to separate motor mounts. The separate motor mounts can be coupled to each other so that one motor mount of the two motor mounts is configured to move with respect to the other motor mount. The movement can be linear movements, e.g., one motor mount can be linearly translated with respect to the other motor mount, to adjust a distance between the two motor shafts. The movement can be rotation movements, e.g., one motor mount can be rotated with respect to the other motor mount, to adjust a distance between the two motor shafts.
In some embodiments, the print head can be coupled to a 3D printer, such as removably coupled. For example, the print head can be coupled to the 3D printer for printing a soft material. The print head can then be removed from the 3D printer, and another print head can be installed for printing a different material.
In some embodiments, an acoustic sensor can be included for detecting a condition of the two motors. The acoustic sensor can be coupled to the print head or to the 3D printer. The acoustic sensor can detect a normal sound, e.g., the amplitude and the frequency of the sound, of the motors when running, and can report that things are running properly. The acoustic sensor can detect an abnormal sound, e.g., from a change in the amplitude and/or the frequency of the sound, of the motors when running, and can report that there seems to be a problem. A controller can decide to stop the printing process, or can automatically adjust an operating condition of the motors, such as changing a speed or changing an acceleration of the motors.
In some embodiments, an acoustic sensor can be included for detecting a contact of the print head with an object. The acoustic sensor can be coupled to the print head or to the 3D printer. For example, the print head can move downward to contact a platform of the 3D printer. Before the contact, the acoustic sensor can detect a normal sound of the motors. After the contact, the sound can change, e.g., changing in the amplitude and/or the frequency of the sound. A controller can determine the location that the print head contact the platform, and can set the location to be a reference point for the platform with respect to the print head.
In some embodiments, an acoustic sensor can be included for leveling a platform of a 3D printer. The acoustic sensor can be coupled to the print head or to the 3D printer. For example, the print head can move to a first point, and then find a first contacting location of the print head with the platform. The print head can move to another point, and can repeat the process to find a second contacting location. With three contacting locations, the 3D printer can level the platform. For example, the platform can be adjusted so that the contacting locations are located in a plane perpendicular to the print head. Alternatively, a software correction algorithm can be used so that the print head can print on a non-perpendicular plane (if the contacting locations are on a plane) or on an irregular surface (if the contacting locations do not form a planar surface).
In some embodiments, the present invention discloses a method to use the print head with two independent motors driving a filament. The method can include activating the two motors to rotate in opposite direction, wherein each motor comprises a shaft, wherein the two shafts are configured to drive a filament along a channel of a conduit to a heated chamber for delivering a molten material. The method can also include moving the motors to print an object with the molten material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art 3D print head according to some embodiments.
FIG. 2 A- 2 E illustrate a configuration for a filament delivery assembly according to some embodiments.
FIGS. 3 A- 3 C illustrate flow charts for filament delivering according to some embodiments.
FIG. 4 A- 4 E illustrate a configuration for a filament delivery assembly according to some embodiments.
FIG. 5 A- 5 E illustrate a configuration for a filament delivery assembly according to some embodiments.
FIG. 6 illustrates a flow chart for filament delivering according to some embodiments.
FIG. 7 A- 7 D illustrate a configuration for a filament delivery assembly according to some embodiments.
FIGS. 8 A- 8 B illustrate flow charts for filament delivering according to some embodiments.
FIG. 9 A- 9 D illustrate a configuration for a filament delivery assembly according to some embodiments.
FIGS. 10 A- 10 C illustrate configurations for a filament delivery assembly according to some embodiments.
FIGS. 11 A- 11 B illustrate flow charts for filament delivering according to some embodiments.
FIGS. 12 A- 12 C illustrate acoustic sensor configurations according to some embodiments.
FIGS. 13 A- 13 C illustrate flow charts for acoustic signal configurations according to some embodiments.
FIGS. 14 A- 14 D illustrate contact sensing configurations using an acoustic sensor assembly according to some embodiments.
FIGS. 15 A- 15 C illustrate contact sensing configurations using an acoustic sensor assembly according to some embodiments.
FIGS. 16 A- 16 C illustrate a leveling configuration using an acoustic sensor assembly according to some embodiments.
FIG. 17 illustrates a 3D printer configuration according to some embodiments.
FIGS. 18 A- 18 D illustrate configurations for 3D printers according to some embodiments.
FIGS. 19 A- 19 B illustrate a flexible layer having carbon fiber mesh according to some embodiments.
FIGS. 20 A- 20 B illustrate configurations for carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 21 A- 21 C illustrate configurations for flexible layers with support structures according to some embodiments.
FIGS. 22 A- 22 B illustrate flow charts for reinforcing flexible layers with carbon fiber mesh according to some embodiments.
FIGS. 23 A- 23 E illustrate a process for forming a carbon fiber mesh reinforce flexible layer according to some embodiments.
FIGS. 24 A- 24 E illustrate a process for forming a carbon fiber mesh reinforce flexible layer according to some embodiments.
FIGS. 25 A- 25 D illustrate configurations of carbon fiber mesh reinforced flexible layers according to some embodiments.
FIG. 26 illustrates a flow chart for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 27 A- 27 C illustrate processes for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIG. 28 illustrates a flow chart for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 29 A- 29 B illustrate processes for forming joints having a carbon fiber mesh reinforced flexible layer according to some embodiments.
FIG. 30 illustrates a flow chart for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 31 A- 31 B illustrate processes for forming surface conditioning 3D printed objects according to some embodiments.
FIGS. 32 A- 32 B illustrate flow charts for forming surface conditioning objects for casting according to some embodiments.
FIGS. 33 A- 33 E illustrate configurations of a molding system according to some embodime
The present application is a continuation of application Ser. No. 15/464,348, filed on Mar. 21, 2017, U.S. Pat. No. 10,926,527, issued on Feb. 23, 2021, entitled â3D printer systems and methodsâ, which claims priority from U.S. Provisional Patent Application Ser. No. 62/310,816, filed on Mar. 21, 2016, entitled: â3D printer systems and methodsâ, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
3D printers can be used to build solid objects by printing layers by layers of building materials. The building materials can be in liquid or semi liquid form at the 3D printer head, for example, a solid material can be heated and then extruded from a 3D printer nozzle. The layers of building materials can be solidified on a substrate.
3D printer systems can use a fused filament fabrication (FFF) process (sometimes called fused deposition modeling (FDM) process) in which a filament is moved, e.g., by a filament moving mechanism, toward a heated zone. The filament can be melted, and extruded on a platform to form a 3D object. The melted filament can adhere to the walls of the heated printer head, resulting in a deformed printed lines.
It would therefore be advantageous to have advanced 3D printing systems and methods that have improved printing mechanisms.
SUMMARY OF THE DESCRIPTION
In some embodiments, the present invention discloses a print head for a 3D printer for printing a structure using a filament. The print head can include two hobbed shafts disposed in opposite sides of the filament and contacting the filament. The shafts can be configured to rotate in opposite directions for driving the filament, for example to a heated chamber. The heated chamber can be configured to heat the filament to a melting temperature, so that the print head can deliver a molten material.
In some embodiments, one shaft of the two shafts can be coupled to a motor, e.g., to be actively driven by the motor. The other shaft can be coupled to the one shaft by a coupling mechanism, such as by a gear set or by a belt.
In some embodiments, each shaft can be coupled to one motor, e.g., two shafts can be coupled to two independent motors. The motors can be independent, e.g., the filament can be actively driven by the two independent motors. The motors can be driven at a same speed or at different speeds, for example, to ensure an appropriate delivering of material to the heated chamber.
In some embodiments, an assembly, such as a spring assembly, can be coupled to the print head to adjust the distance between the two shafts. The adjustment can be used to change a friction with the filament, e.g., a driving force to the filament. For example, a soft filament might need a smaller distance to ensure an appropriate force to the filament to drive the filament.
The print head can be coupled to a 3D printer, such as movably coupled, e.g., the print head can be securely coupled to the 3D printer and can be removed from the 3D printer.
In some embodiments, the print head can include a conduit having a channel for guiding the filament. The diameter of the channel can be about the size of the filament, so that the filament can easily move within the channel. Further, the conduit can include a low friction material, such as Teflon, which can assist in the movements of the filament.
The print head can include two motors with each motor having a shaft. The motors are configured to drive the filament along the channel by contact, e.g., the motor shafts can be in contact with the filament, so that the motors turn, the friction with the filament can drive the filament. The contact can be a direct contact, e.g., the motor shafts can directly contact the filament. To increase a friction force, a portion of the surface of the shafts can be hobbed, e.g., roughened. The hobbed surfaces can then contact the filament for driving the filament.
The contact can be an indirect contact, e.g., the motor shafts can contact the filament through an element fixedly coupled to the shafts. For example, a gear or a disc with an irregular circumference surface can be coupled to a shaft. The teeth of the gear of the irregular surface can increase a friction while in contact with the filament. The high friction can assist in moving the filament along the guiding channel.
In some embodiments, the conduit can include two cut portions for accepting the two shafts or the gears (e.g., a gear or a disc) fixedly coupled to the shafts. The cut portions can be at two opposite side of the conduit, cut through the conduit until reaching the channel. Each cut portion can expose a portion of the channel. A shaft can pass through the cut portion, with a portion of the shaft surface, e.g., the hobbed surface, contacting the filament through the corresponded exposed portion. Alternatively, a shaft can pass through the cut portion, with a gear surface contacting the filament through the corresponded exposed portion. With the conduit having the cut portions, the filament is constrained in the intended path, e.g., along the channel direction. The conduit can ease the insertion of the filament to the print head, since the filament just need to enter the conduit. Subsequent movements of the filament can be guided by the conduit. The conduit can also prevent the accumulation of filament in the area under the shafts, especially if the downstream of the filament path is blocked. Essentially, the conduit almost completely covers the filament, e.g., the cut portions can expose sections of the filament, but the exposed sections are blocked by the shafts or the gears.
In some embodiments, the shafts can be disposed in parallel with each other and perpendicular to the conduit. The shafts can be configured to be in opposite sides of the filament and contacting the filament. The motors can be disposed in opposite directions with respect to the conduit. The shafts can be configured to rotate in opposite directions for driving the filament along the channel.
In some embodiments, an assembly can be coupled to one shaft or one motor or one motor mount, for example, for pushing the one shaft to the other shaft, e.g. for adjusting a distance between the two shafts. The assembly can be spring loaded.
In some embodiments, the motors can be coupled to separate motor mounts. The separate motor mounts can be coupled to each other so that one motor mount of the two motor mounts is configured to move with respect to the other motor mount. The movement can be linear movements, e.g., one motor mount can be linearly translated with respect to the other motor mount, to adjust a distance between the two motor shafts. The movement can be rotation movements, e.g., one motor mount can be rotated with respect to the other motor mount, to adjust a distance between the two motor shafts.
In some embodiments, the print head can be coupled to a 3D printer, such as removably coupled. For example, the print head can be coupled to the 3D printer for printing a soft material. The print head can then be removed from the 3D printer, and another print head can be installed for printing a different material.
In some embodiments, an acoustic sensor can be included for detecting a condition of the two motors. The acoustic sensor can be coupled to the print head or to the 3D printer. The acoustic sensor can detect a normal sound, e.g., the amplitude and the frequency of the sound, of the motors when running, and can report that things are running properly. The acoustic sensor can detect an abnormal sound, e.g., from a change in the amplitude and/or the frequency of the sound, of the motors when running, and can report that there seems to be a problem. A controller can decide to stop the printing process, or can automatically adjust an operating condition of the motors, such as changing a speed or changing an acceleration of the motors.
In some embodiments, an acoustic sensor can be included for detecting a contact of the print head with an object. The acoustic sensor can be coupled to the print head or to the 3D printer. For example, the print head can move downward to contact a platform of the 3D printer. Before the contact, the acoustic sensor can detect a normal sound of the motors. After the contact, the sound can change, e.g., changing in the amplitude and/or the frequency of the sound. A controller can determine the location that the print head contact the platform, and can set the location to be a reference point for the platform with respect to the print head.
In some embodiments, an acoustic sensor can be included for leveling a platform of a 3D printer. The acoustic sensor can be coupled to the print head or to the 3D printer. For example, the print head can move to a first point, and then find a first contacting location of the print head with the platform. The print head can move to another point, and can repeat the process to find a second contacting location. With three contacting locations, the 3D printer can level the platform. For example, the platform can be adjusted so that the contacting locations are located in a plane perpendicular to the print head. Alternatively, a software correction algorithm can be used so that the print head can print on a non-perpendicular plane (if the contacting locations are on a plane) or on an irregular surface (if the contacting locations do not form a planar surface).
In some embodiments, the present invention discloses a method to use the print head with two independent motors driving a filament. The method can include activating the two motors to rotate in opposite direction, wherein each motor comprises a shaft, wherein the two shafts are configured to drive a filament along a channel of a conduit to a heated chamber for delivering a molten material. The method can also include moving the motors to print an object with the molten material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art 3D print head according to some embodiments.
FIG. 2 A- 2 E illustrate a configuration for a filament delivery assembly according to some embodiments.
FIGS. 3 A- 3 C illustrate flow charts for filament delivering according to some embodiments.
FIG. 4 A- 4 E illustrate a configuration for a filament delivery assembly according to some embodiments.
FIG. 5 A- 5 E illustrate a configuration for a filament delivery assembly according to some embodiments.
FIG. 6 illustrates a flow chart for filament delivering according to some embodiments.
FIG. 7 A- 7 D illustrate a configuration for a filament delivery assembly according to some embodiments.
FIGS. 8 A- 8 B illustrate flow charts for filament delivering according to some embodiments.
FIG. 9 A- 9 D illustrate a configuration for a filament delivery assembly according to some embodiments.
FIGS. 10 A- 10 C illustrate configurations for a filament delivery assembly according to some embodiments.
FIGS. 11 A- 11 B illustrate flow charts for filament delivering according to some embodiments.
FIGS. 12 A- 12 C illustrate acoustic sensor configurations according to some embodiments.
FIGS. 13 A- 13 C illustrate flow charts for acoustic signal configurations according to some embodiments.
FIGS. 14 A- 14 D illustrate contact sensing configurations using an acoustic sensor assembly according to some embodiments.
FIGS. 15 A- 15 C illustrate contact sensing configurations using an acoustic sensor assembly according to some embodiments.
FIGS. 16 A- 16 C illustrate a leveling configuration using an acoustic sensor assembly according to some embodiments.
FIG. 17 illustrates a 3D printer configuration according to some embodiments.
FIGS. 18 A- 18 D illustrate configurations for 3D printers according to some embodiments.
FIGS. 19 A- 19 B illustrate a flexible layer having carbon fiber mesh according to some embodiments.
FIGS. 20 A- 20 B illustrate configurations for carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 21 A- 21 C illustrate configurations for flexible layers with support structures according to some embodiments.
FIGS. 22 A- 22 B illustrate flow charts for reinforcing flexible layers with carbon fiber mesh according to some embodiments.
FIGS. 23 A- 23 E illustrate a process for forming a carbon fiber mesh reinforce flexible layer according to some embodiments.
FIGS. 24 A- 24 E illustrate a process for forming a carbon fiber mesh reinforce flexible layer according to some embodiments.
FIGS. 25 A- 25 D illustrate configurations of carbon fiber mesh reinforced flexible layers according to some embodiments.
FIG. 26 illustrates a flow chart for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 27 A- 27 C illustrate processes for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIG. 28 illustrates a flow chart for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 29 A- 29 B illustrate processes for forming joints having a carbon fiber mesh reinforced flexible layer according to some embodiments.
FIG. 30 illustrates a flow chart for forming carbon fiber mesh reinforced flexible layers according to some embodiments.
FIGS. 31 A- 31 B illustrate processes for forming surface conditioning 3D printed objects according to some embodiments.
FIGS. 32 A- 32 B illustrate flow charts for forming surface conditioning objects for casting according to some embodiments.
FIGS. 33 A- 33 E illustrate configurations of a molding system according to some embodiments.
FIGS. 34 A- 34 C illustrate different print heads according to some embodiments.
FIGS. 35 A- 35 I illustrate different conditioning heads according to some embodiments.
FIGS. 36 A- 36 B illustrate flow charts for casting objects using surface conditioning printed objects according to some embodiments.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Additive manufacturing processes generally fabricate 3D objects by depositing layers by layers in patterns corresponding to the shape of the objects. At each layer, a print head can deposit building materials at locations corresponded to the pattern of the object for that layer.
3D printing processes can include inkjet printing, stereolithography and fused filament fabrication. In inkjet printing processes, liquid material are released from an inkjet print head, and solidified on the substrate surface, e.g., on the model being formed. In stereolithography processes, a UV light can crosslink layers of photopolymer. In fused filament fabrication processes, a continuous filament of thermoplastic can be softened or melted and then re-solidified on a previously deposited layer. Alternatively, paste-like materials can be used for printing, for example, through a pressure extrusion device such as a piton/cylinder.
Various polymers are used, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), high density polyethylene (HDPE), PC/ABS, and polyphenylsulfone (PPSU). Other materials can be used, such as clay or ceramic materials.
FIG. 1 illustrates a prior art 3D print head according to some embodiments. The print head 100 can be used in a 3D printer system, which can print objects on a platform. The platform can include a heater, which can heat the platform surface. The print head can be moved relative to the platform, in horizontal and vertical directions, for example, by computer controlled mechanisms using stepper or servo motors. For example, the printer head can move in a horizontal direction, such as x. The platform can move in a horizontal direction such as y, together with a vertical direction such as z. Other movement configurations can be used to provide complete 3D movements of the printer head relative to the platform.
The print head 100 can accept a filament 110 , such as a thermoplastic filament. The print head 100 can include a delivery mechanism to regulate the flow of the filament 110 . For example, a motor rotating a gear 120 can be used to push the filament into a heated chamber 150 at a controlled rate. There can be bearing 130 , disposed on an opposite side of the rotating gear 120 for supporting the filament against the rotating gear 120 .
The heated chamber 150 can include a heater 152 , which can heat the filament 110 to a temperature that can melt or soften the filament material, for example, to a temperature higher than the glass transition temperature of the filament material. A temperature sensor 154 can be used to regulate the temperature of the heated chamber 150 . A nozzle 160 can be used to control the size of the molten filament, outputted from the print head.
The print head can be thermally isolated from the delivery assembly, for example, by a low thermal conductivity material. For example, a thermal isolation element 140 can be disposed between the heated chamber 150 and the rotating gear 120 , for example, to prevent heating other components of the print head. The thermal isolation element 140 can also be function as a guide, which can serve for guiding the filament 110 , from the rotating gear 120 to the heated chamber 150 .
There can be a gap 170 between the rotating gear 120 and the guiding element 140 . The filament can escape through the gap 170 , for example, if there is a blockage at the guiding element 140 or at the heated chamber 150 .
In addition, the there might not be enough force for the rotating gear 120 to push the filament 110 . Since there can be only one rotating gear 120 pushing the filament against the rotating bearing 130 , if there is a blockage, the rotating gear 120 can be slipped. Further, if the filament includes a soft material, such as an elastic material or a deformable material, the single rotating gear 120 might deform the filament without actually moving it toward the guiding element 140 .
In some embodiments, the present invention discloses a novel filament delivery assembly to deliver a filament. The filament delivery assembly can be used in a print head of a 3D printer system. The novel filament delivery assembly can include a filament guiding assembly and a filament driving assembly, which can include an active drive element, such as a motor rotating a hobbed shaft, for driving a filament in the filament guiding assembly toward a heated chamber.
In some embodiments, the present invention discloses a print head for use, for example, in a 3D printer system. The print head can include a novel filament delivery assembly.
The filament delivery assembly can include a hollow conduit, which can enclose a filament therein for guiding the filament. The hollow conduit can include an opening at an end, which can operate as an input for accepting the filament. The other end of the hollow conduit can be coupled to the heated chamber, e.g., for guiding the filament along the hollow conduit toward the heated chamber. The hollow conduit can be extended from the heated chamber to pass a filament driving assembly, such as a hobbed shaft of a motor or a tooth gear coupled to a shaft of a motor. The filament driving assembly can be located between the input of the hollow conduit and the heated chamber.
The hollow conduit can be configured for supporting the filament against the filament driving assembly, e.g., against the hobbed shaft or a gear shaft of a motor. The hollow conduit can eliminate spaces after the filament driving assembly, e.g., between the filament driving assembly and the heated chamber, thus can reduce potential filament mis-guiding problems. In addition, the hollow conduit can simplify the print head construction, for example, by eliminating the bearing assembly that is used as a support the filament driving assembly.
FIG. 2 A- 2 E illustrate a configuration for a filament delivery assembly according to some embodiments. A filament delivery assembly 200 can be used in a print head, which can include coupling elements for coupling to movement assemblies, e.g., for moving in x, y, or z directions, of a 3D printer system. The print head can include a heated chamber 250 , which can accept a filament input from the filament delivery assembly, and deliver molten filament to a nozzle 260 for printing on a platform. The heated chamber 250 can include a heater 252 and a temperature sensor 254 , for regulating a temperature of the heated chamber.
A filament delivery assembly 200 can include a filament driving assembly 220 , which can include a motor 222 driving a hobbled shaft or a gear shaft. For example, FIG. 2 D shows a motor 270 having a shaft 271 coupled with a gear 272 . The uneven surface of the gear can touch the filament, and when the shaft is rotated, the gear is also rotated, and the uneven surface of the gear can move the filament. FIG. 2 E shows a motor 275 having a shaft 276 hobbed 272 277 , e.g., forming a rough or uneven surface or teeth on a surface of the shaft. For example, the hobbing action can form marking on the shaft, which can generate a rough surface. The rough surface of the hobbed portion of the shaft can touch the filament, and when the shaft is rotated, the rough surface of the shaft can catch the filament to move the filament.
A filament delivery assembly 200 can be include a filament guiding assembly, which can include a hollow conduit 240 . The hollow conduit can include a material with low friction, such as Teflon. The hollow conduit can include a material with low thermal conductivity for thermal isolation, e.g., reducing the amount of heat that can reach the filament driving assembly from the heated chamber.
The hollow conduit 240 can include an input opening at one end for accepting a filament 210 . The hollow conduit 240 can include an opening at an opposite end for coupling with the heated chamber, e.g., to guide the filament toward the heated chamber. The hollow conduit 240 can include a cut portion 225 , which can allow the motor shaft 220 to pass through for contacting the filament. When the motor rotates, the filament can be pulled into the hollow conduit from the input opening. The motor can also push the filament, along the hollow conduit, toward the heated chamber.
The hollow conduit can cover, e.g., guide, the filament before the filament reaches the filament driving assembly 220 , such as the rotating gear or hobbed portion of the motor shaft. The filament can be guided after the pushing action of the filament driving assembly, thus the filament delivery assembly can prevent or eliminate spilling of the filament, such as preventing the filament from being driven to another location when the heated chamber is blocked.
In some embodiments, the hollow conduit can include holes 245 , for example, to increase a thermal isolation from the heated chamber to the motor shaft. A fan can be included, for blowing passing the holes and the hollow conduit, further reducing a temperature at the motor shaft.
In some embodiments, a force can be applied to push the hollow conduit 240 relative to the motor shaft 220 . The force can be used to increase a friction between the motor shaft and the filament, which can prevent slippage of the filament. As shown, a force 233 can be used to push the hollow conduit against the motor shaft. Alternatively, a force can be applied to the motor to push the motor shaft against the hollow conduit.
FIGS. 3 A- 3 C illustrate flow charts for filament delivering according to some embodiments. In FIG. 3 A , operation 300 guides a filament between a filament driving assembly and a filament heating assembly. The filament can also be guided before and/or during the filament driving assembly. The complete filament guidance can prevent mis-directing of the filament, for example, in unexpected events such as a blockage in the filament heating assembly.
In FIG. 3 B , operation 320 provides a hollow conduit for accepting a filament. Operation 340 330 forms a cut in the conduit for passing a filament driving assembly, wherein the filament driving assembly is coupled to the filament for driving the filament along the conduit. The cut can be formed by drilling a hole through the hollow conduit. The hole can be configured to expose a portion of the filament to an outside ambient, e.g., the hole diameter can be larger than a thickness of the hollow conduit, and after formed, the hole can expose the hollow portion of the hollow conduit to the outside ambient. The hole diameter can be slightly larger than a diameter of the hobbed portion of a motor shaft, or slightly larger than a diameter of a gear coupled to a motor shaft.
In some embodiments, holes can be formed on the hollow conduit. A spring assembly can be incorporated for pushing the hollow conduit against the filament driving assembly. Support elements can be added around the hollow conduit, for example, for supporting the hollow conduit and/or supporting the filament driving assembly, such as a motor.
In FIG. 3 C , operation 350 uses a hollow conduit to guide a filament with a filament driving assembly driving the filament along the conduit. The filament driving assembly can include a motor having a motor shaft. A gear can be fixed coupled to the motor shaft. Alternatively, the motor shaft can be hobbed for forming rough surface on a portion of the motor shaft. The rough surface can contact the filament, and can move the filament along the hollow portion of the hollow conduit.
In some embodiments, the present invention discloses a novel filament delivery assembly to deliver a filament, together with a print head incorporating the filament delivery assembly. The filament delivery assembly can include a filament driving assembly, which can include an active drive element, such as a motor rotating a hobbed shaft, and a follower element, such as a rotatable bearing that can be pressed against the active drive element.
The filament delivery assembly can include a hollow conduit, which can enclose a filament therein for guiding the filament. The hollow conduit can be extended from the heated chamber to pass a filament driving assembly, such as a hobbed shaft of a motor or a tooth gear coupled to a shaft of a motor. The filament driving assembly can be located between the input of the hollow conduit and the heated chamber. The hollow conduit can eliminate spaces after the filament driving assembly, e.g., between the filament driving assembly and the heated chamber, thus can reduce potential filament mis-guiding problems.
The filament delivery assembly can include a rotatable element, such as a bearing, which can assist in pushing the filament toward active drive element, such as a hobbed portion of a motor shaft. The bearing can also be hobbed, for example, to reduce slippage to the filament.
FIG. 4 A- 4 E illustrate a configuration for a filament delivery assembly according to some embodiments. A filament delivery assembly 400 can be used in a print head, which can include coupling elements for coupling to movement assemblies, e.g., for moving in x, y, or z directions, of a 4D printer system. The print head can include a heated chamber 450 , which can accept a filament 410 input from the filament delivery assembly, and deliver molten filament to a nozzle 460 for printing on a platform. The heated chamber 450 can include a heater 452 and a temperature sensor 454 , for regulating a temperature of the heated chamber.
A filament delivery assembly 400 can include a filament driving assembly 420 , which can include an active drive element such as a motor 422 driving a hobbled shaft or a gear shaft. The filament driving assembly can include a follower element, such as a rotatable element such as a bearing 430 . The active drive element and the follower element can be pushed against the filament, such as pushing in opposite directions. The active drive element can drive the filament along a filament guiding assembly, and the follower element can assist in maintaining appropriate friction between the active element and the filament.
A filament delivery assembly 400 can be include a filament guiding assembly, which can include a hollow conduit 440 . The hollow conduit can include a material with low friction, such as Teflon. The hollow conduit can include a material with low thermal conductivity for thermal isolation, e.g., reducing the amount of heat that can reach the filament driving assembly from the heated chamber.
The hollow conduit 440 can include a cut portion 425 , which can allow the motor shaft 420 to pass through for contacting the filament. The hollow conduit 440 can include another cut portion 435 , which can allow the rotatable bearing 430 having a bearing shaft 437 to pass through for contacting the filament. The cut portions
425 and 435 can be slightly larger than a diameter of the hobbed motor shaft 420 and the bearing 430 , respectively, for allowing the motor shaft and the bearing to drive the filament along the hollow conduit. The cut portions can cut through the hollow conduit, e.g., by a drill bit.
When the motor rotates, the filament can be pulled into the hollow conduit from the input opening. The movement of the filament can rotate the rotatable bearing. The motor can also push the filament, along the hollow conduit, toward the heated chamber.
In some embodiments, the hollow conduit can include holes, for example, to increase a thermal isolation from the heated chamber to the motor shaft. A fan can be included, for blowing passing the holes and the hollow conduit, further reducing a temperature at the motor shaft.
In some embodiments, a force can be applied to push the follower element, e.g., the rotatable bearing 430 relative to the motor shaft 420 . The force can be used to increase a friction between the motor shaft and the filament, which can prevent slippage of the filament. As shown, a force 433 can be used to push the rotatable bearing against the motor shaft. Alternatively, a force can be applied to the motor to push the motor shaft against the rotatable bearing.
FIG. 5 A- 5 E illustrate a configuration for a filament delivery assembly according to some embodiments. A filament delivery assembly 500 can be used in a print head, including a heated chamber 550 .
A filament delivery assembly 500 can include a filament driving assembly 520 , which can include an active drive element such as a motor 522 driving a hobbled shaft or a gear shaft. The filament driving assembly can include a follower element, such as a rotatable element such as a bearing 530 .
A filament delivery assembly 500 can be include a filament guiding assembly, which can include a hollow conduit 540 . The hollow conduit 540 can include a cut portion 525 , which can allow the motor shaft 520 to pass through for contacting the filament. The hollow conduit 540 can include a partial cut portion 535 , which can accept the rotatable bearing 530 having a bearing shaft 537 for contacting the filament. The cut portions
525 and 535 can be slightly larger than a diameter of the hobbed motor shaft 520 and the bearing 530 , respectively, for allowing the motor shaft and the bearing to drive the filament along the hollow conduit. The cut portion 525 for the motor shaft can cut through the hollow conduit, e.g., by a drill bit. The cut portion 535 for the motor shaft can be a partial cut, e.g., not cutting through as the cut portion 525 , but cutting only a part of the hollow conduit. The partial cut 535 can have flanges 539 , formed due to the partial cut, e.g., not cutting through the hollow conduit. The flanges 539 can assist in keeping the rotatable bearing in place, e.g., not sliding along the shaft 537 to positions away from the filament 510 .
In some embodiments, the hollow conduit can include holes, for example, to increase a thermal isolation from the heated chamber to the motor shaft. A fan can be included, for blowing passing the holes and the hollow conduit, further reducing a temperature at the motor shaft.
In some embodiments, a force can be applied to push the follower element, e.g., the rotatable bearing 530 relative to the motor shaft 520 . The force can be used to increase a friction between the motor shaft and the filament, which can prevent slippage of the filament. As shown, a force 533 can be used to push the rotatable bearing against the motor shaft. Alternatively, a force can be applied to the motor to push the motor shaft against the rotatable bearing.
FIG. 6 illustrates a flow chart for filament delivering according to some embodiments. Operation 600 provides a hollow conduit for accepting a filament. Operation 610 forms a first cut in the conduit for passing a filament driving assembly, wherein the filament driving assembly is coupled to the filament for driving the filament along the conduit. The first cut can be a through cut, for example, by drilling through the hollow conduit at a side. The first cut can cut to the hollow portion of the hollow conduit, exposing the hollow interior, or exposing a portion of the filament if the filament is placed in the hollow conduit. The first cut can be slightly larger than a diameter of the hobbed portion of a motor shaft, or slightly larger than a diameter of a gear coupled to a motor shaft.
Operation 620 forms a second cut in the conduit for passing a rolling assembly, wherein the rolling assembly is coupled to the filament for rolling the filament along the conduit. The second cut can be a through cut, for example, by drilling through the hollow conduit at a side. The second cut can cut to the hollow portion of the hollow conduit, exposing the hollow interior, or exposing a portion of the filament if the filament is placed in the hollow conduit.
The second cut can be a partial cut, for example, by cutting at a side of the hollow conduit, while leaving flanges around the partial cut. For example, the rolling assembly can include a rotatable bearing having a bearing thickness less than an outside diameter of the hollow conduit. The second cut can be a cut having a width slightly larger than the bearing thickness. Since the bearing thickness is smaller than the outside diameter of the hollow conduit, the second cut can leave flanges in the hollow conduit around the bearing.
The second cut can cut to the
CLAIMS
Claims ( 20 )
What is claimed is:
1. A print head comprising
two motors each comprises a shaft,
wherein the two shafts are configured to rotate in opposite directions for driving a filament,
wherein each motor is coupled to a motor mount,
wherein the two motor mounts are coupled to each other so that one motor mount of the two motor mounts is configured to move with respect to the other motor mount,
wherein one motor mount of the two motor mounts is coupled through an assembly configured for adjusting a distance between the two motor mounts,
a heated chamber,
wherein the heated chamber is configured to receive the filament driven by the two shafts,
wherein the heated chamber is configured to deliver a molten material.
2. A print head as in claim 1 ,
wherein at least one shaft of the two shafts is roughened at a portion of the shaft,
wherein the roughened portion of the shaft is configured to contact the filament.
3. A print head as in claim 1 ,
wherein the two shafts are disposed in parallel with each other and perpendicular to the filament,
wherein the two shafts are configured to be in opposite sides of the filament.
4. A print head as in claim 1 ,
wherein a gear is coupled to at least one shaft of the two shafts,
wherein the gear is configured to contact the filament.
5. A print head as in claim 1 ,
wherein the two motors are disposed in opposite directions with respect to the filament.
6. A print head as in claim 1 ,
wherein the print head is configured to be coupled to a 3D printer.
7. A print head as in claim 1 , further comprising
an acoustic sensor for detecting a condition of the two motors.
8. A print head as in claim 1 , further comprising
an acoustic sensor for detecting a contact of the print head with an object.
9. A print head as in claim 1 , further comprising
an acoustic sensor for leveling a platform of a 3D printer.
10. A print head comprising
two motors each comprises a shaft,
wherein the two shafts are configured to rotate in opposite directions for driving a filament,
a heated chamber,
wherein the heated chamber is configured to receive the filament driven by the two shafts,
wherein the heated chamber is configured to deliver a molten material,
an acoustic sensor configured for leveling a platform of a 3D printer.
11. A print head as in claim 10 ,
wherein at least one shaft of the two shafts is roughened at a portion of the shaft,
wherein the roughened portion of the shaft is configured to contact the filament.
12. A print head as in claim 10 ,
wherein each motor of the two motors is coupled to a motor mount,
wherein the print head further comprises an assembly coupled to one motor mount of the two motor mounts for adjusting a distance between the two motor mounts.
13. A print head as in claim 10 ,
wherein each motor is coupled to a motor mount,
wherein the two motor mounts are coupled to each other so that one motor mount of the two motor mounts is configured to move with respect to the other motor mount,
wherein one motor mount of the two motor mounts is coupled to an assembly for adjusting a distance between the two motor mounts.
14. A print head as in claim 10 ,
wherein the print head is configured to be coupled to a 3D printer.
15. A print head as in claim 10 , further comprising
an acoustic sensor for detecting a condition of the two motors.
16. A print head comprising
two motors each comprises a shaft,
wherein the two shafts are configured to rotate in opposite directions for driving a filament,
wherein at least one shaft of the two shafts of the two motors is configured to directly contact the filament,
wherein the at least one shaft is roughened at a portion of the shaft that contacts the filament,
a heated chamber,
wherein the heated chamber is configured to receive the filament driven by the two shafts,
wherein the heated chamber is configured to deliver a molten material.
17. A print head as in claim 16 ,
wherein each motor of the two motors is coupled to a motor mount,
wherein the print head further comprises an assembly coupled to one motor mount of the two motor mounts for adjusting a distance between the two motor mounts.
18. A print head as in claim 16 ,
wherein the print head is configured to be coupled to a 3D printer.
19. A print head as in claim 16 , further comprising
an acoustic sensor for detecting a condition of the two motors.
20. A print head as in claim 16 , further comprising
an acoustic sensor for leveling a platform of a 3D printer.
US17/181,079
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3D printer systems and methods
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3D printer systems and methods
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2016-03-21
2021-02-22
3D printer systems and methods
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