Material deposition system for additive manufacturing

• US 10,137,679 B2
• Filed: 10/29/2015
• Issued: 11/27/2018
• Est. Priority Date: 10/29/2015
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Brennan, Michael
• Primary Examiner(s): Hauth, Galen H
• Application Number:
  US14/926,645
• Publication Number:
  US 20170120513A1
• Time in Patent Office: 1,125 Days
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29B 7/401 having a casing closely surrounding the rotor, e.g. with a plunger for feeding the material B29B7/407, B29B7/42 take precedence
• CPC Class Codes: B29B 7/404 with feeding or valve actuating means, e.g. with cleaning means
• CPC Class Codes: B29B 7/407 with a casing closely surrounding the rotor, e.g. with conical rotor
• CPC Class Codes: B29B 7/42 with screw or helix
• CPC Class Codes: B29B 7/48 with intermeshing devices, e.g. screws
• CPC Class Codes: B29B 7/726 Measuring properties of mixture, e.g. temperature or density B29B7/724 takes precedence
• CPC Class Codes: B29B 7/728 Measuring data of the driving system, e.g. torque, speed, power, vibration B29B7/724 takes precedence
• CPC Class Codes: B29C 2948/922 Viscosity; Melt flow index [MFI]; Molecular weight
• CPC Class Codes: B29C 2948/926 Flow or feed rate
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 48/285 Feeding the extrusion material to the extruder
• CPC Class Codes: B29C 48/802 Heating
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• 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 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes

Abstract

A material deposition system for additive manufacturing including an extruder and a measuring device for measuring the viscosity and/or other rheological properties of a build material contained within the extruder. The measuring device may provide feedback to a controller for controlling one or more parameters depending on the measured viscosity and/or other rheological properties of the build material within the extruder. Two or more feed materials may be supplied to the extruder and a mixing device may be configured to mix the feed materials within the extruder to create a blended deposition material. The mixing device may be operatively coupled to the measuring device for simultaneously measuring the viscosity and/or other rheological properties of the materials during mixing. The controller may be configured to independently control one or more parameters associated with the materials depending on the viscosity and/or other rheological properties measured by the measuring device.

Claims

1. A material deposition system for additive manufacturing comprising:

an extruder having;

two or more input ports for receiving two or more feed materials,

a mixing chamber for receiving the two or more feed materials supplied from the two or more input ports,

a mixing device for mixing the two or more feed materials in the mixing chamber to create a blended deposition material, and

an extrusion port for extruding the blended deposition material;

two or more actuators, each of the two or more actuators being configured to independently feed a respective one of the two or more feed materials at a feed rate toward the mixing chamber;

a measuring device configured to measure the viscosity and/or other rheological properties of the blended deposition material in the mixing chamber; and

a controller operatively coupled to the measuring device and operatively coupled to the two or more actuators;

wherein the controller is configured to receive information from the measuring device corresponding to the measured viscosity and/or other rheological properties of the blended deposition material in the mixing chamber; and

wherein the controller is configured to adjust the respective feed rates of the two or more actuators independently of one another in response to the information received from the measuring device corresponding to the measured viscosity and/or other rheological properties of the blended deposition material in the mixing chamber.

2. The material deposition system according to claim 1, wherein the mixing device includes a static mixer.

3. The material deposition system according to claim 1, wherein the mixing device includes a dynamic mixer.

4. The material deposition system according to claim 1, wherein the mixing device is operatively coupled to the measuring device.

5. The material deposition system according to claim 4, wherein the mixing device is integral with the measuring device.

6. The material deposition system according to claim 1, wherein the measuring device includes a viscometer.

7. The material deposition system according to claim 6, wherein the mixing device includes a dynamic mixer;

and

wherein the viscometer is operatively coupled to the dynamic mixer for measuring the torsional forces generated during the mixing of the two or more feed materials and/or the mixing of the blended deposition material.

8. The material deposition system according to claim 1, wherein the measuring device includes a rheometer.

9. The material deposition system according to claim 8, wherein the mixing chamber is cylindrical and wherein the mixing device is spaced from an interior surface of the mixing chamber to define an annulus therebetween;

and

wherein the rheometer is operatively coupled to the mixing device for measuring the torsional forces generated during the mixing of the two or more feed materials and/or the mixing of the blended deposition material in the annulus.

10. The material deposition system according to claim 1, further comprising one or more heating elements configured to heat the two or more feed materials and/or the blended deposition material.

11. The material deposition system according to claim 10, wherein the controller includes a temperature controller configured to control temperature as one of the one or more parameters of the controller;

wherein the temperature controller is operatively coupled to the one or more heating elements, the temperature controller being configured to control temperature of the two or more feed materials and/or the blended deposition material depending on the viscosity and/or other rheological properties measured by the measuring device.

12. The material deposition system according to claim 1, wherein the extruder includes two or more liquefication passages, each of the two or more liquefication passages being associated with a respective one of the two or more input ports for receiving a respective one of the two or more feed materials;

the material deposition system further including two or more heating elements, each of the two or more heating elements being in thermal communication with a corresponding one of the two or more liquefication passages, the two or more heating elements each being configured to independently heat and liquefy the respective feed materials, each of the liquefication passages being upstream of the mixing chamber and configured to deliver the respective liquefied feed materials downstream toward the mixing chamber;

wherein the temperature controller is operatively coupled to each of the two or more heating elements and is configured to adjust temperature of each of the two or more heating elements independently of one another in response to the information received from the measuring device corresponding to the measured viscosity and/or other rheological properties of the blended deposition material in the mixing chamber.

13. The material deposition system according to claim 12, further including a chamber heating element in thermal communication with the mixing chamber for heating the blended deposition material,

wherein the controller is operatively coupled to the chamber heating element to control temperature of the blended deposition material depending on the viscosity and/or other rheological properties measured by the measuring device.

14. The material deposition system according to claim 1, wherein the controller includes a mix speed controller configured to control speed of the mixing device depending on the viscosity and/or other rheological properties measured by the measuring device.

15. The material deposition system according to claim 1, wherein the controller includes a flow controller configured to control flow rate of the blended deposition material extruded from the extrusion port depending on the viscosity and/or other rheological properties measured by the measuring device.

16. The material deposition system according to claim 1, in combination with the two or more feed materials, wherein at least one of the two or more feed materials is different from another one of the two or more feed materials for creating different compositions of the blended deposition material.

17. An additive manufacturing apparatus comprising:

a build platform, and

the material deposition system according to claim 1.

18. A method for fabricating a three-dimensional article comprising:

providing the material deposition system according to claim 1;

supplying two or more feed materials in a flowable state to the mixing chamber of the extruder;

mixing the two or more flowable feed materials in the mixing chamber to create the blended deposition material;

measuring the viscosity and/or other rheological properties of the two or more flowable feed materials or the blended deposition material; and

controlling one or more parameters associated with the two or more flowable feed materials and/or the blended deposition material in response to the measured viscosity and/or other rheological properties of the two or more flowable feed materials and/or the blended deposition material; and

dispensing the blended deposition material from the extrusion port.

19. A material deposition system for additive manufacturing comprising:

an extruder having;

two or more input ports for receiving two or more feed materials,

two or more liquefication passages, each of the two or more liquefication passages being associated with a respective one of the two or more input ports for receiving a respective one of the two or more feed materials,

a mixing chamber downstream of the two or more liquefication passages for receiving the two or more feed materials from the two or more liquefication passages,

a mixing device for mixing the two or more feed materials in the mixing chamber to create a blended deposition material, and

an extrusion port for extruding the blended deposition material;

two or more heating elements, each of the two or more heating elements being in thermal communication with a corresponding one of the two or more liquefication passages, the two or more heating elements each being configured to independently heat and liquefy the respective feed material upstream of the mixing chamber to thereby deliver the respective liquefied feed material downstream toward the mixing chamber for mixing thereof;

a measuring device configured to measure the viscosity and/or other rheological properties of the blended deposition material in the mixing chamber; and

a controller operatively coupled to the measuring device and operatively coupled to the two or more heating elements;

wherein the controller is configured to receive information from the measuring device corresponding to the measured viscosity and/or other rheological properties of the blended deposition material in the mixing chamber; and

wherein the controller is configured to adjust temperatures of the two or more heating elements independently of one another in response to the information received from the measuring device corresponding to the measured viscosity and/or other rheological properties of the blended deposition material in the mixing chamber.