Color switching for three-dimensional printing

• US 10,022,917 B2
• Filed: 10/26/2015
• Issued: 07/17/2018
• Est. Priority Date: 09/07/2012
• Status: Active Grant

• Current Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Original Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Inventors: Pax, Charles E.
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): NGUYEN, THUKHANH T
• Application Number:
  US14/922,325
• Publication Number:
  US 20160039151A1
• Time in Patent Office: 995 Days
• Field of Search: 264129, 2641761, 264 401, 264 407, 264308, 425145, 425150, 425375, 425112, 425113, 700118, 700119, 700120, 226 8, 226 24, 226 26, 226 42, 226 43, 226 45
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/321 Feeding
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

By reversing the direction of a first build material fed into an extruder, the first build material can be wholly or partially evacuated from the extruder before a second material is introduced. This approach mitigates transition artifacts and permits faster, more complete changes from one build material to another.

Claims

1. A computer program product for switching filaments in a three-dimensional printer, the computer program product comprising non-transitory computer executable code embodied in a memory of a three-dimensional printer having an extruder with a first input port, a second input port, an extrusion port, and a chamber coupling the first input port, the second input port, and the extrusion port in fluid communication, the chamber disposed within the extruder and heated to liquefy filaments received through the first input port and the second input port, wherein the computer executable code, when executing on a controller of the three-dimensional printer, controls the three-dimensional printer to perform the steps of:

driving a first build material through the first input port until the first build material extrudes through the extrusion port;

withdrawing the first build material through the first input port a predetermined amount, wherein the predetermined amount is selected to move a material transition region between the first build material and a second build material out of the chamber but not enough to completely withdraw the first build material from the extruder; and

driving a second build material through the second input port until the second build material extrudes through the extrusion port.

2. The computer program product of claim 1 further comprising code that controls the three-dimensional printer to perform the step of heating the chamber to liquefy at least one of the first build material and the second build material.

3. The computer program product of claim 1 wherein the first build material is a different color than the second build material.

4. The computer program product of claim 1 wherein the first build material is of a different type than the second build material.

5. The computer program product of claim 1 wherein the first build material is a plastic.

6. The computer program product of claim 1 wherein the first build material is one or more of ABS, PLA, and PCL.

7. The computer program product of claim 1 wherein the predetermined amount includes an amount of the first build material displacing at least one half the volume of the chamber.

8. The computer program product of claim 1 wherein the predetermined amount includes an amount of the first build material displacing at least the volume of the chamber.

9. The computer program product of claim 1 further comprising code that controls the three-dimensional printer to perform the step of withdrawing the first build material concurrently with driving the second build material.

10. The computer program product of claim 1 further comprising code that controls the three-dimensional printer to perform the step of withdrawing the second build material through the second input port by a second predetermined amount and driving the first build material through the first input port until the first build material extrudes through the extrusion port.

11. A three-dimensional printer comprising:

an extruder having a first input port, a second input port, an extrusion port, and a chamber coupling the first input port, the second input port, and the extrusion port in fluid communication, the chamber disposed within the extruder and heated to liquefy filaments received through the first input port and the second input port; and

a controller including computer executable code that, when executing on the controller, causes the three-dimensional printer to switch the extrusion port from a first build material passing through the first input port, the chamber, and the extrusion port to a second build material supplied at the second input port by performing the steps of withdrawing the first build material through the first input port a predetermined amount, wherein the predetermined amount is selected to move a material transition region between the first build material and a second build material out of the chamber but not enough to completely withdraw the first build material from the extruder, and driving the second build material through the second input port until the second build material extrudes through the extrusion port.

12. The three-dimensional printer of claim 11 further comprising a heating element coupled to the controller and configured to heat the chamber to liquefy at least one of the first build material and the second build material.

13. The three-dimensional printer of claim 11 wherein the first build material is a different color than the second build material.

14. The three-dimensional printer of claim 11 wherein the predetermined amount includes an amount of the first build material displacing at least one half a volume of the chamber.

15. The three-dimensional printer of claim 11 wherein the predetermined amount includes an amount of the first build material displacing at least a volume of the chamber.

16. The three-dimensional printer of claim 11 wherein the controller is further configured to withdraw the first build material concurrently with driving the second build material.

17. The three-dimensional printer of claim 11 wherein the controller is further configured to switch from the second build material to the first build material by withdrawing the second build material through the second input port by a second predetermined amount and driving the first build material through the first input port until the first build material extrudes through the extrusion port.

18. A three-dimensional printer comprising:

an extruder having a first input port, a second input port, an extrusion port, and a chamber disposed within the extruder and coupling the first input port, the second input port, and the extrusion port in fluid communication; and

a controller including computer executable code that, when executing on the controller, causes the three-dimensional printer to switch the extrusion port from a first build material passing through the first input port, the chamber, and the extrusion port to a second build material supplied at the second input port by performing the steps of;

withdrawing the first build material through the first input port a predetermined amount, wherein the predetermined amount is selected to move a material transition region out of the chamber but not enough to completely withdraw the first build material from the extruder, the material transition region defined by an identifiable volume that includes mixing between the first build material and the second build material; and

driving the second build material through the second input port until the second build material extrudes through the extrusion port.