3D printing devices and methods

• US 10,513,076 B1
• Filed: 06/06/2018
• Issued: 12/24/2019
• Est. Priority Date: 06/06/2017
• Status: Active Grant

• Current Assignee: Connecting Products Inc.
• Original Assignee: Connecting Products Inc.
• Inventors: Freakes, Anthony
• Primary Examiner(s): Khare, Atul P.
• Application Number:
  US16/001,305
• Time in Patent Office: 566 Days
• CPC Class Codes: B29C 2035/1658 using gas
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/194 during lay-up
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/232 for motion along the axis orthogonal to the plane of a layer
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/295 Heating elements
• 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

Abstract

3D printers include a feed stepper motor coupled to an extruder, a platen positioned adjacent the extruder, a platen support coupled to a platen lifter, and directional stepper motors, wherein the extruder comprises an air scoop, extruder nozzle and heater, wherein the heater is positioned to heat the extruder nozzle and air to provide heated air and the air scoop is configured and positioned to route the heated air which is emitted adjacent the extruder nozzle directly onto the surface of a workpiece positioned on the platen. A feed stepper motor may include a hollow bore motor shaft. A substrate made of the same material being extruded may be provided. A method of 3D printing employs such a substrate.

Claims

1. A method of 3D printing by a 3D printing device, the method comprising:

providing a 3D printing device comprising an extruder for extruding a filament material, wherein the extruder comprises an extrusion nozzle, a heater positioned within the extruder to heat both the extrusion nozzle and cooling air, a platen, and an air scoop positioned within the extruder to redirect a portion of the cooling air under heating applied by the heater and before being emitted as heated air adjacent the extrusion nozzle;

coupling a substrate to the platen;

providing the cooling air to the filament material so as to maintain a temperature of the filament material, a portion of the cooling air then being directed into an opening of and through the air scoop;

heating the extrusion nozzle and the portion of the cooling air passing through the air scoop to provide heated air, the air scoop redirecting the portion of the air toward the substrate during said heating;

routing the heated air directly onto the substrate to heat the substrate;

extruding the filament material through the extruder; and

creating a workpiece on the substrate by applying the extruded filament material to the heated substrate.

2. The method of 3D printing according to claim 1 further comprising removing the substrate and the workpiece from the platen and removing at least a part of the substrate from the workpiece.

3. The method of 3D printing according to claim 1, said routing comprising routing the heated air via the air scoop directly onto a top surface of the substrate.

4. The method of 3D printing according to claim 1 wherein the cooling air is fan driven.

5. The method of 3D printing according to claim 1 wherein the substrate is made from the same material as the filament material.

6. The method of 3D printing according to claim 1 wherein the maintained temperature of the filament material is well below its softening temperature.

7. The method of 3D printing according to claim 1 wherein said heating of the extrusion nozzle causes heating of the cooled filament material.