METHODS FOR FIBER REINFORCED ADDITIVE MANUFACTURING

• US 20150165691A1
• Filed: 09/19/2014
• Published: 06/18/2015
• Est. Priority Date: 03/22/2013
• Status: Active Grant

• Current Assignee: MarkForged, Inc
• Original Assignee: MarkForged, Inc
• Inventors: MARK, Gregory Thomas, BENHAIM, David, PARANGI, Abraham, SKLAROFF, Benjamin
• Granted Patent: US 9,694,544 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 70/16 using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29K 2025/08 Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene B29K2055/02 takes precedence
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/085 Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives 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: G05B 15/02 electric
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]

Abstract

A three-dimensional geometry is received, and sliced into layers. A first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material is generated defining at least part of an interior of a first layer. A second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material defines at least part of an interior of a second layer. A generated isotropic fill material tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

Claims

1. A method for generating three-dimensional toolpath instructions for a three dimensional printer, the method comprising:

receiving a three-dimensional geometry;

slicing the three-dimensional geometry into layers;

generating an isotropic fill material tool path for controlling a three dimensional printer to deposit a substantially isotropic fill material, wherein the generated isotropic tool path defines at least part of a perimeter of the first layer;

generating an anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material, wherein an anisotropic characteristic of the substantially anisotropic fill material is oriented relative to a trajectory of the anisotropic fill tool path, and wherein the generated anisotropic tool path defines at least part of an interior of the first layer.

2. The method according to claim 1, wherein generating an anisotropic fill tool path further comprises:

generating an anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material in a location adjacent to and reinforcing a negative subcontour within an interior of the first layer.

3. The method according to claim 1, wherein generating an anisotropic fill tool path further comprises:

generating a second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material, the second anisotropic fill toolpath being computed based on the first anisotropic fill tool path and being in a location adjacent to and reinforcing the first anisotropic tool path of the first layer.

4. The method according to claim 3, wherein the second anisotropic fill toolpath is located within the first layer.

5. The method according to claim 3, wherein the second anisotropic fill toolpath is located within a second layer adjacent to the first layer.

6. The method according to claim 5, wherein the generated first anisotropic tool path defines at least part of an interior of a first layer and includes a first start point, and wherein the generated second anisotropic tool path defines at least part of an interior of a second layer, and includes a second start point offset from the first start point.

7. The method according to claim 5, wherein the generated first anisotropic tool path defines at least part of an interior of a first layer and includes a first crossover to an adjacent portion of the first anisotropic toolpath, and wherein the generated second anisotropic tool path defines at least part of an interior of a second layer, and includes a second crossover to an adjacent portion of the second anisotropic toolpath, the second crossover being offset from the first crossover.

8. The method according to claim 1, wherein generating an anisotropic fill tool path further comprises:

generating a second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material, the second anisotropic fill toolpath being computed based on the first anisotropic fill tool path and the first and second anisotropic toolpaths establishing a centroid therebetween;

generating an isotropic fill material tool path for controlling a three dimensional printer to deposit a substantially isotropic fill material, wherein the generated isotropic tool path is proximate the centroid and defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

9. The method according to claim 1, wherein generating an anisotropic fill tool path further comprises:

generating the anisotropic fill tool path following an irregular trajectory including an offset from a compound subcontour boundary.

10. The method according to claim 9, wherein generating an anisotropic fill tool path further comprises:

generating crossovers between adjacent offsets of the anisotropic fill tool path, wherein the cross-overs are arranged on a curved portion of the anisotropic fill tool path.

14. The method according to claim 1, wherein generating a first anisotropic fill tool path further comprises:

generating a third anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material, the third anisotropic fill toolpath being computed based on the first anisotropic fill tool path and being in a location adjacent to and reinforcing the first anisotropic tool path of the first layer.

15. The method according to claim 14, wherein the third anisotropic fill toolpath is located within the first layer.

16. The method according to claim 14, wherein the third anisotropic fill toolpath is located within a second layer adjacent to the first layer.

18. The method according to claim 1, wherein the generated first anisotropic tool path defines at least part of an interior of a first layer and includes a first crossover to an adjacent portion of the first anisotropic toolpath, and wherein the generated second anisotropic tool path defines at least part of an interior of a second layer, and includes a second crossover to an adjacent portion of the second anisotropic toolpath, the second crossover being offset from the first crossover.

19. The method according to claim 1, wherein generating a first anisotropic fill tool path further comprises:

generating the first anisotropic fill tool path following an irregular trajectory including an offset from a compound subcontour boundary.

20. The method according to claim 19, wherein generating a first anisotropic fill tool path further comprises:

generating crossovers between adjacent offsets of the first anisotropic fill tool path, wherein the cross-overs are arranged on a curved portion of the first anisotropic fill tool path.

11. A method for generating three-dimensional toolpath instructions for a three dimensional printer, the method comprising:

receiving a three-dimensional geometry;

slicing the three-dimensional geometry into layers;

generating an first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material, and wherein the generated first anisotropic tool path defines at least part of an interior of a first layer;

generating a second anisotropic fill tool path for controlling a three dimensional printer to deposit the substantially anisotropic fill material, and wherein the generated second anisotropic tool path defines at least part of an interior of a second layer,

generating an isotropic fill material tool path for controlling a three dimensional printer to deposit a substantially isotropic fill material, wherein the generated isotropic tool path defines at least part of a perimeter and at least part of an interior of a third layer intervening between the first and second layers.

12. The method according to claim 11, further comprising:

generating the second anisotropic fill toolpath based on the first anisotropic fill tool path and the first and second anisotropic toolpaths establishing a centroid therebetween;

generating the isotropic fill material tool path for controlling a three dimensional printer to deposit a substantially isotropic fill material, wherein the generated isotropic tool path is proximate the centroid.

13. The method according to claim 11, wherein generating a first anisotropic fill tool path further comprises:

generating the first anisotropic fill tool path for controlling a three dimensional printer to deposit a substantially anisotropic fill material in a location adjacent to and reinforcing a negative subcontour within an interior of the first layer.

17. The method according to claim 11, wherein the generated first anisotropic tool path defines at least part of an interior of a first layer and includes a first start point, and wherein the generated second anisotropic tool path defines at least part of an interior of a second layer, and includes a second start point offset from the first start point.