Three-dimensional printer tool systems

• US 10,525,692 B2
• Filed: 10/24/2018
• Issued: 01/07/2020
• Est. Priority Date: 11/15/2013
• Status: Active Grant

• Current Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Original Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Inventors: Schmehl, Peter Joseph, Kemperle, Aljosa, Schmehl, Stewart
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Nguyen, Thu Khanh T
• Application Number:
  US16/169,991
• Publication Number:
  US 20190061335A1
• Time in Patent Office: 440 Days
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/266 Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
• CPC Class Codes: B29C 48/2888 in band or in strip form, e.g. rubber strips
• CPC Class Codes: B29C 48/832 Heating
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/30 Auxiliary operations or equipment
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29L 2009/00 Layered products
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling

Abstract

An extruder or other similar tool head of a three-dimensional printer is slidably mounted along a feedpath of build material so that the extruder can move into and out of contact with a build surface according to whether build material is being extruded. The extruder may be spring-biased against the forward feedpath so that the extruder remains above the build surface in the absence of applied forces, and then moves downward into a position for extrusion when build material is fed into the extruder. In another aspect, modular tool heads are disclosed that can be automatically coupled to and removed from the three-dimensional printer by a suitable robotics system. A tool crib may be provided to store multiple tool heads while not in use.

Claims

1. A three-dimensional printer comprising:

a drive assembly including a power train configured to drive a filament of a build material along an axis of a feedpath for the filament;

an extruder configured to removably and replaceably couple to the three-dimensional printer in a predetermined alignment to the axis of the feedpath through one or more registration features that align the extruder to the axis of the feedpath when the extruder is placed for use in the three-dimensional printer;

an extrusion head moveably coupled to the extruder to permit movement of the extrusion head within a predetermined range of linear displacement along the axis of the feedpath relative to the extruder, the extrusion head including an input and a nozzle disposed along the axis of the feedpath when the extruder is placed for use in the three-dimensional printer, the input coupled to the nozzle by a chamber within the extrusion head for passage of the filament;

a heat sink coupled to the extrusion head; and

a spring coupled to the extruder that biases the extrusion head and the heat sink away from the drive assembly along the feedpath when the extruder is placed for use in the three-dimensional printer, wherein the axis of the feedpath passes through the extrusion head when the extruder is placed for use in the three-dimensional printer, and wherein spring includes a coil spring disposed about the axis of the feedpath.

2. The three-dimensional printer of claim 1 further comprising one or more magnets to magnetically couple the extruder to a mount of the three-dimensional printer to resist displacement of the extruder when placed for use in the three-dimensional printer.

3. The three-dimensional printer of claim 2 wherein a surface of the extruder is configured to support the extruder against displacement along the axis of the feedpath under a force applied by the filament to the extrusion head when the extruder is placed onto a mount of the three-dimensional printer.

4. The three-dimensional printer of claim 2 wherein the extruder is coupled in a fixed relationship to the drive assembly along the axis of the feedpath when the extruder is placed for use in the three-dimensional printer.

5. The three-dimensional printer of claim 1 wherein the spring biases the extrusion head relative to the extruder with a predetermined spring force.

16. The three-dimensional printer of claim 1 further comprising circuitry within the extruder to identify the extruder to the three-dimensional printer.

6. A three-dimensional printer comprising:

a drive assembly including a power train configured to drive a filament along an axis of a feedpath through the three-dimensional printer;

a mount;

an extruder removably and replaceably coupled to the mount; and

an extrusion head including an input and a nozzle disposed along the axis of the feedpath when the extruder is placed for use in the three-dimensional printer, the input coupled to the nozzle by a chamber within the extrusion head for passage of the filament, the extrusion head moveably coupled to the extruder to permit movement of the extrusion head along the axis of the feedpath relative to the extruder;

a heat sink coupled to the extrusion head; and

a spring coupled to the extruder that biases the extrusion head and the heat sink away from the drive assembly along the feedpath when the extruder is placed for use in the three-dimensional printer, wherein the axis of the feedpath passes through the extrusion head when the extruder is placed for use in the three-dimensional printer, and wherein spring includes a coil spring disposed about the axis of the feedpath.

7. The three-dimensional printer of claim 6 further comprising one or more registration features to align the extruder to the mount when the extrusion head is placed for use in the three-dimensional printer.

8. The three-dimensional printer of claim 6 further comprising one or more load bearing surfaces to support the extrusion head within a predetermined range of linear displacement along the axis of the feedpath.

9. The three-dimensional printer of claim 6 further comprising a heating element adjacent to the extrusion head and positioned to liquefy the filament along a portion of the feedpath.

10. The three-dimensional printer of claim 6 further comprising a filament detector to detect a presence of the filament at a location along the feedpath.

11. The three-dimensional printer of claim 6 further comprising one or more mechanical stops to limit axial travel of the extrusion head along the axis of the feedpath.

12. The three-dimensional printer of claim 6 further comprising one or more magnets positioned to magnetically couple the extruder to a surface of the three-dimensional printer, and to resist displacement of the extruder when placed for use in the three-dimensional printer.

13. The three-dimensional printer of claim 6 further comprising circuitry within the extruder to identify the extruder to the three-dimensional printer.

14. The three-dimensional printer of claim 6 further comprising circuitry to identify the extruder in a manner that can be detected through a connector by the three-dimensional printer when the extruder is placed for use in the three-dimensional printer.

15. The three-dimensional printer of claim 14 wherein the circuitry is configured to identify the extrusion head by at least one of a diameter, a type, a size, a shape, and a serial number.