Additive manufacturing technique for printing three-dimensional parts with printed receiving surfaces

• US 10,399,281 B2
• Filed: 04/29/2016
• Issued: 09/03/2019
• Est. Priority Date: 08/16/2012
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Mannella, Dominic F., Swanson, William J.
• Primary Examiner(s): Hauth, Galen H
• Application Number:
  US15/142,528
• Publication Number:
  US 20160236421A1
• Time in Patent Office: 1,222 Days
• CPC Class Codes: B22F 10/22 Direct deposition of molten metal
• CPC Class Codes: B22F 10/43 characterised by material
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/38 Housings, e.g. machine housings
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 5/10 of articles with cavities or holes, not otherwise provided for in the preceding subgroups
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• 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
• CPC Class Codes: B64C 3/00 Wings ornithopter wings B64C33/02
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method for printing three-dimensional parts with an additive manufacturing system, comprising printing successive layers having increasing cross-sectional areas, and printing layers of a three-dimensional part onto the previously printed layers, where a last layer of the previously printed successive layers has a cross-sectional area that is at least as large as a footprint area of the three-dimensional part.

Claims

1. A method for printing three-dimensional parts in a layer by layer manner with an extrusion-based additive manufacturing system, the method comprising:

providing a starter piece having a receiving surface that is substantially parallel to a build plane and where the receiving surface is substantially normal to a print axis;

extruding a first layer of a three-dimensional part and/or a sacrificial structure onto the receiving surface by extruding material from a print head;

moving the starter piece and a printed portion of the three-dimensional part and/or the sacrificial structure a distance along the print axis,

extruding a successive layer of the three-dimensional part and/or the sacrificial structure onto the previously printed layer; and

repeating the moving and extruding steps to print the three dimensional part to a dimension greater than a build environment of the additive manufacturing system.

2. The method of claim 1, wherein printing the sacrificial structure comprises extruding a water soluble material.

3. The method of claim 1, wherein printing the sacrificial structure comprises extruding a part material.

4. The method of claim 1, wherein the print axis is substantially horizontal.

5. The method of claim 1, wherein the print axis is substantially vertical.

6. The method of claim 1, wherein the print axis is at an angle between substantially horizontal and substantially vertical.

7. The method of claim 1, wherein the build environment comprises a chamber with a port wherein as the three-dimensional part is printed to a dimension greater than the build chamber, at least a portion of the part extends through the port.

8. The method of claim 7, and further comprising heating the chamber while the three-dimensional part is printed in a layer by layer manner.

9. The method of claim 1, and wherein printing the support structure comprises printing layers of a scaffold for the three-dimensional part, wherein the scaffold braces the three-dimensional part to address forces in the build plane as the three-dimensional part is printed.

10. The method of claim 8, wherein the scaffold is printed to have a configuration that causes spaced apart periodic contact with the three-dimensional part being printed.

11. The method of claim 1, and further comprising engaging the starter piece and subsequently printed layers of the part or the sacrificial structure with a drive mechanism of the additive manufacturing system to move the starter piece along the printing axis.

12. A method for printing three-dimensional parts in a layer by layer manner with an extrusion-based additive manufacturing system, the method comprising:

providing a starter piece having a receiving surface substantially parallel to a build plane and wherein the receiving surface is substantially normal to a print axis;

providing an electronic model of a three-dimensional part;

slicing the electronic model into a plurality of layers;

generating tool paths for each layer of the plurality of layers;

extruding each layer of the plurality of layers in the print plane with the extrusion-based additive manufacturing system based on the generated tool paths wherein the three-dimensional part is secured to the receiving surface of the starter piece such that the starter piece and a printed portion of the three-dimensional part move together along the print axis; and

repeating the extrusion and moving steps until the three-dimensional part is printed wherein a length of the three-dimensional part is greater than a length of a build environment of the additive manufacturing system.

13. The method of claim 12, and further comprising extruding a support structure along with the plurality of layers of the three-dimensional part, wherein printing the three-dimensional part onto the printed successive layers comprises extruding the three-dimensional part onto the support structure in a layer-by-layer manner.

14. The method of claim 12, and further comprising:

generating tool paths for each layer of the plurality of layers of the three dimensional part and scaffolds of the support structure; and

extruding the scaffold onto the extruded prior layer, wherein the scaffold braces the three-dimensional part against forces parallel to the build plane.

15. The method of claim 14, wherein the scaffold is extruded to have a configuration that causes spaced apart periodic contact with the three-dimensional part being printed.

16. The method of claim 12, wherein the print axis is substantially horizontal.

17. The method of claim 12, wherein the print axis is substantially vertical.

18. The method of claim 12, wherein the print axis is at an angle between substantially horizontal and substantially vertical.

19. The method of claim 12, wherein the build environment comprises a chamber with a port wherein as the three-dimensional part is printed to a dimension greater than the build chamber, at least a portion of the part extends through the port.

20. The method of claim 19, and further comprising heating the chamber while the three-dimensional part is printed in a layer by layer manner.