METHOD AND APPARATUS FOR 3D FABRICATION

• US 20160031159A1
• Filed: 07/29/2015
• Published: 02/04/2016
• Est. Priority Date: 07/29/2014
• Status: Active Grant

• Current Assignee: Nscrypt Incorporated
• Original Assignee: Nscrypt Incorporated
• Inventors: Church, Kenneth H., Chen, Xudong, Goldfarb, Josh, Owens, Michael W., Deffenbaugh, Paul, Silva, Daniel, Newton, Charles Michael
• Granted Patent: US 10,500,830 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 48/2566 Die parts
• CPC Class Codes: B29C 48/25686 for dies
• 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 48/872 characterised by differential heating or cooling
• CPC Class Codes: B29C 48/873 in the direction of the stream of the material
• 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 64/112 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 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• 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

An apparatus for use in 3D fabrication includes a heat sink, a melt tube extending through the heat sink, the melt tube having a first end and an opposite second end and adapted for melting filament or other material as the material is conveyed from the first end to the second end, a pen tip having an opening therein for ejecting melted material, the pen tip at the second end of the melt tube, and a pen tip holder for securely holding the pen tip during printing, the pen tip holder having a heater element associated therewith.

Claims

6. The apparatus of claim wherein the melt tube comprises a stainless steel tube.

20. A method for fabricating an object, the method comprising:

providing an apparatus for use in fused filament fabrication, the apparatus comprising (a) a heat sink, (b) a melt tube extending through the heat sink, the melt tube having a first end and an opposite second end and adapted for melting material as the material is conveyed from the first end to the second end, (c) a pen tip having an opening therein for ejecting melted material, the pen tip at the second end of the melt tube, and (d) a pen tip holder for securely holding the pen tip, the pen tip holder having a heater element associated therewith;

receiving the material into the melt tube;

melting the material while in the melt tube to provide melted material;

dissipating heat from the melt tube through the heat sink;

conveying the melted material from the pen tip to form a portion of the object.

1. An apparatus for use in 3-D fabrication, the apparatus comprising:

a heat sink configured to dissipate heat;

a melt tube extending through the heat sink, the melt tube having a first end and an opposite second end and adapted for melting a material as the material is conveyed from the first end to the second end;

a pen tip having an opening therein for ejecting melted material, the pen tip at the second end of the melt tube; and

a pen tip holder configured to securely hold the pen tip disposed apart from the heat sink, the pen tip holder having a heater element associated therewith.

2. The apparatus of claim 1 wherein the pen tip, the pen tip holder, and the heater element form an integrated part with the heater element conformally printed on the pen tip or pen tip holder.

3. The apparatus of claim 1 further comprising a cooling unit for cooling the first end of the melt tube.

4. The apparatus of claim 3 wherein the cooling unit comprises a fan to provide forced air cooling of the first end of the melt tube.

5. The apparatus of claim 1 wherein the melt tube is comprised of metal.

7. The apparatus of claim 1 wherein the pen tip has a cone-shaped profile.

8. The apparatus of claim 1 further comprising a body wherein portions of the apparatus are disposed within the body and wherein wiring is printed on a side of the body.

9. The apparatus of claim 1 wherein the pen tip comprises a ceramic material.

10. The apparatus of claim 1 wherein the heater element comprises a heater stick positioned within the pen tip holder.

11. The apparatus of claim 1 wherein the heater element comprises a heater coil positioned within the pen tip holder.

12. The apparatus of claim 1 further comprising a cooling unit to selectively cool a portion of the apparatus.

13. The apparatus of claim 1 further comprising a heating system configured to selectively heat a portion of a build unit.

14. The apparatus of claim 1 wherein the heating system comprises a laser, an infrared heat source, or an ultrasonic wave generator.

15. The apparatus of claim 1 further comprising a hopper and an auger for conveying the filament.

16. The apparatus of claim 1 wherein the material comprises filaments.

17. The apparatus of claim 16 wherein the filaments comprise plastic.

18. The apparatus of claim 1 wherein the material comprises metal.

19. The apparatus of claim 1 wherein the material comprises powder.

21. The method of claim 20 further comprising selectively heating or cooling portions of the apparatus.

22. The method of claim 20 further comprising selectively heating portions of the object.

23. The method of claim 20 further comprising receiving the filament from a hopper via an auger.

24. The method of claim 20 wherein the material is a filament.

25. The method of claim 24 wherein the filament comprises plastic.

26. The method of claim 20 wherein the material comprises metal.

27. The method of claim 20 wherein the pen tip is disposed apart from the heat sink by the pen tip holder.

26-1. The method of claim 20 wherein the material comprises a powder.