Systems, devices, and methods for high-throughput three-dimensional printing

• US 10,562,227 B2
• Filed: 09/09/2016
• Issued: 02/18/2020
• Est. Priority Date: 12/01/2015
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Go, Jamison, Hart, Anastasios John
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Moreno Hernandez, Jerzi H
• Application Number:
  US15/260,813
• Publication Number:
  US 20170151704A1
• Time in Patent Office: 1,257 Days
• CPC Class Codes: B29C 48/0023 combined with printing or marking
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• 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 48/2886 of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
• CPC Class Codes: B29C 48/865 Heating
• CPC Class Codes: B29C 48/873 in the direction of the stream of the material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/321 Feeding
• 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

Printing devices and methods are provided that utilize high throughput extrusion to generate a printer material, such as a three-dimensional object. High-throughput extrusion systems as provided volumetrically pre-heat an extruded filament to a desired pre-heat temperature, and then either maintain or heat the extruded filament to a desired melt temperature prior to having the filament extruded out of the system and onto a surface, such as a build platform. By pre-heating the filament prior to heating it to the temperature at which it is excluded, it helps increase the throughput of the system. Likewise, by doing the heating volumetrically, it further helps increase the throughput of the system. Various embodiments of devices and methods typically used for printing in conjunction with the disclosed high throughput systems are also provided.

Claims

1. An extrusion system, comprising:

an extruder;

a pre-heater in fluid communication with the extruder; and

a liquefier in fluid communication with the pre-heater,

wherein the extruder is configured to advance a filament through the pre-heater and the liquefier towards a build platform,

wherein the pre-heater comprises an infrared radiation source, an infrared reflector chamber next to the infrared radiation source and a transparent flow channel arranged within the infrared reflector chamber and configured to receive the filament from the extruder, the infrared radiation source and the infrared reflector chamber are configured to transmit infrared radiation to the filament as the filament is advanced by the extruder through the transparent flow channel to volumetrically raise a temperature of the filament to at least a desired pre-heat temperature in a substantially uniform manner across a volume of the filament that extends normal to a longitudinal axis of the filament, and

wherein the liquefier is configured to maintain or raise the temperature of the filament that passed through the pre-heater to at least a desired melt temperature prior to the filament exiting the liquefier, towards the build platform.

2. The extrusion system of claim 1, further comprising:

a gantry; and

a cart having the liquefier coupled thereto,

wherein the gantry is configured to move the cart in an X-Y plane to position the liquefier to one or more target X-Y coordinates in the X-Y plane.

3. The extrusion system of claim 2, wherein the gantry is an H-frame gantry.

4. The extrusion system of claim 2, further comprising:

the build platform towards which the filament is extruded after it exits the liquefier, the build platform being configured to be positioned on one or more Z coordinates along a Z-axis that interests the X-Y plane,

wherein the gantry and build platform are configured to operate together such that filament extruded by the extruder through the liquefier is extruded onto one or more target X-Y-Z coordinates.

5. A printer for printing three-dimensional objects, the printer comprising the extrusion system of claim 4.

6. The extrusion system of claim 1, wherein the pre-heater and the liquefier are disposed within a housing of a single heating unit.

7. The extrusion system of claim 1, wherein the extruder is a nut feed extruder, the extruder further comprising a rotatable feed nut having one or more internal engagement features that are configured to engage one or more complementary mating external engagement features disposed on the filament advanced by the extruder to impart a force on the one or more complementary mating external engagement features and advance the filament through the pre-heater and the liquefier towards the build platform upon rotation of the feed nut.

8. The extrusion system of claim 7, wherein the rotatable feed nut is configured to advance the filament towards the build platform by rotating about an axis along which the filament is fed into the feed nut, the feed nut having internal engagement features formed thereon that are configured to engage with the filament such that the feed nut applies force to the filament along the feed axis.

9. The extrusion system of claim 7, wherein the filament is a threaded filament and the one or more complementary mating external engagement features are one or more external threads that are complementary to the one or more internal engagement features of the rotatable feed nut such that the one or more internal engagement features are configured to impart a force on the one or more external threads to advance the filament towards the build platform upon rotation of the feed nut.

10. The extrusion system of claim 9,

wherein the threaded filament comprises a first material that melts when it is heated to the desired melt temperature and a second material that remains solid or less viscous than the first material when they are heated to the desired melt temperature.

11. The extrusion system of claim 7, wherein the internal engagement features of the feed nut and the external engagement features of the filament comprise one or more complementary geometric configurations selected from the group consisting of:

mating periodic textures, triangles, rectangles, and threads.

12. The extrusion system of claim 7, wherein the extruder comprises a die configured to generate one or more engagement features on an exterior of filament advanced by the extruder.

13. The extrusion system of claim 1, further comprising a controller configured to adjust at least one of power supplied to the pre-heater, power supplied to the liquefier, and force applied to a feed nut of the extruder to modify at least one of the desired pre-heat temperature, the desired melt temperature, and a feed rate of the extruder based on received real-time parameters of the system, the real-time parameters including at least one of the following parameters:

(1) an extrusion force applied by the extruder on the filament advanced by the extruder;

(2) the feed rate of the extruder;

(3) a temperature of the filament prior to the filament entering the pre-heater;

(4) a temperature of the filament prior to the filament entering the liquefier; and

(5) a temperature of the filament prior to or concurrently with the filament exiting the liquefier, towards the build platform.

14. The extrusion system of claim 1, wherein the pre-heater is configured to create heat-flux across the volume of the filament in a direction extending normal to a longitudinal axis of the filament in an instantaneous or nearly instantaneous manner.

15. The extrusion system of claim 1, wherein the extrusion system is configured to deposit the filament at a rate of at least 200 millimeters per second.

16. An extrusion system, comprising:

an extruder including a feed nut, the feed nut being configured to advance a filament towards a build platform by rotating about a feed axis along which the filament is fed into the feed nut, and the feed nut having one or more internal engagement features formed thereon that are configured to engage with the filament such that the feed nut applies force to the filament along the feed axis;

a pre-heater in fluid communication with the extruder; and

a liquefier in fluid communication with the pre-heater,

wherein the pre-heater comprises an infrared radiation source, an infrared reflector chamber next to the infrared radiation source, and a transparent flow channel arranged within the infrared reflector chamber and configured to receive the filament from the extruder, the infrared radiation source and the infrared reflector chamber are configured to transmit infrared radiation to the filament as the filament is advanced by the extruder through the transparent flow channel to volumetrically raise a temperature of the filament to at least a desired pre-heat temperature in a substantially uniform manner across a volume of the filament that extends normal to a longitudinal axis of the filament, and

wherein the liquefier is configured to maintain or raise the temperature of the filament that passed through the pre-heater to at least a desired melt temperature prior to the filament exiting the liquefier, towards the build platform.

17. The extrusion system of claim 16, wherein the extruder comprises a die configured to generate one or more engagement features on an exterior of filament advanced by the extruder.

18. The extrusion system of claim 16, wherein the one or more internal engagement features are substantially perpendicular to the feed axis when they engage the filament.

19. The extrusion system of claim 16, wherein the one or more internal engagement features are configured to engage one or more complementary engagement features formed on an outer surface of the filament.

20. The extrusion system of claim 16, wherein the filament is a threaded filament and the one or more complementary mating external engagement features are one or more external threads that are complementary to the one or more internal engagement features of the feed nut such that the one or more internal engagement features are configured to impart a force on the one or more external threads to advance the filament through the extruder upon rotation of the feed nut.

21. The extrusion system of claim 20,

wherein the threaded filament comprises a first material that melts when it is heated to the desired melt temperature and a second material that remains less viscous than the first material when they are heated to the desired melt temperature, and

wherein the second material is more conductive than the first material.

22. The extrusion system of claim 16, wherein the one or more internal engagement features of the feed nut and one or more external engagement features of the filament comprise one or more complementary geometric configurations selected from the group consisting of:

mating periodic textures, triangles, rectangles, and threads.

23. The extrusion system of claim 16, wherein the pre-heater is configured to create heat-flux across the volume of the filament in a direction extending normal to a longitudinal axis of the filament in an instantaneous or nearly instantaneous manner.

24. The extrusion system of claim 16, wherein the extrusion system is configured to deposit the filament at a rate of at least 200 millimeters per second.