MODULAR USER-CONFIGURABLE MULTI-PART 3D LAYERING SYSTEM AND HOT END ASSEMBLY

• US 20160067920A1
• Filed: 09/04/2015
• Published: 03/10/2016
• Est. Priority Date: 09/04/2014
• Status: Active Grant

• Current Assignee: Stacker, LLC
• Original Assignee: Stacker, LLC
• Inventors: Fontaine, Norston
• Granted Patent: US 10,456,992 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 64/393 for controlling or regulating additive manufacturing processes
• 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

Apparatus and associated methods for a user configurable modular 3D layering system provide a modular frame assembly, and two or more deposition print heads that are user-configurably disposed along an X-axis carriage drive system. A deposition-receiving tray may have a configurable Z-axis throw. In an exemplary embodiment, an X-axis carriage drive system may include one or more sensors for detecting a starting position of the print heads. For example, the sensor may be a micro-switch engageable by one or more print heads. In an exemplary embodiment, the print heads are removable from the X-axis carriage assembly. In some embodiments, each print head may operate independently of adjacent print heads. In an exemplary embodiment, each print head may include an injection nozzle for depositing the filament. In some embodiments, a y-carriage assembly may include a height sensor for the tray.

Claims

1. A layer deposition system to form a plurality of 3D products simultaneously, the system comprising:

a deposition frame housing having first opposing lateral members extending orthogonal to a first axis, and second opposing lateral members extending orthogonal to a second axis coplanar with and orthogonal to the first axis;

a carriage assembly extending between the first opposing lateral members and parallel to the first axis;

a substrate surface extending between the first opposing lateral members and between the second opposing lateral members;

a plurality of deposition modules releasably coupled to the carriage assembly, each separated from adjacent ones of the plurality of deposition modules by user-predetermined spacings, and operable to deposit material through a nozzle to form a three dimensional product supported by the substrate surface;

a first axis drive coupled to synchronously displace the plurality of deposition modules a predetermined distance along the first axis;

a second axis drive coupled to synchronously displace the plurality of deposition modules a predetermined distance along the second axis; and

,

a third axis drive couple to synchronously create a relative displacement between each of the plurality of deposition modules and the substrate surface along a third axis orthogonal to both the first axis and the second axis.

2. The system of claim 1, wherein the deposition frame housing defines a first interior volume through which the substrate surface is vertically displaceable in response to operation of the third axis drive.

3. The system of claim 2, further comprising a first modular base frame having third opposing lateral members extending orthogonal to the first axis, and fourth opposing lateral members extending orthogonal to the second axis and defining a second interior volume through which the substrate surface is vertically displaceable in response to operation of the third axis drive.

4. The system of claim 3, wherein the first modular base frame is stackable underneath the deposition frame housing.

5. The system of claim 4, wherein the first modular base frame defines a second interior volume that substantially aligns with the first interior volume when the deposition frame housing is stacked on the first modular base frame.

6. The system of claim 1, wherein the carriage assembly releasably engages without tools to at least one of the plurality of deposition modules.

7. The system of claim 1, further comprising a plurality of filament supply modules operable to simultaneously supply a solid filament material to each one of the nozzles of the deposition modules.

8. The system of claim 1, wherein the carriage assembly comprises at least one guide rod to which at least one of the plurality of deposition modules is configured to releasably attach without tools at a user-predetermined separation between adjacent ones of the plurality of deposition modules.

9. The system of claim 8, wherein at least one of the deposition modules is configured to provide slidable engagement parallel to the first axis and along the at least one guide rod.

10. The system of claim 1, wherein the first axis drive releasably engages each one of the plurality of deposition modules to impart synchronous displacement in the direction of the first axis.

11. A method for layer deposition to form a plurality of 3D products simultaneously, the method comprising:

providing a deposition frame housing having first opposing lateral members extending orthogonal to a first axis, and second opposing lateral members extending orthogonal to a second axis coplanar with and orthogonal to the first axis;

providing a carriage assembly extending between the first opposing lateral members and parallel to the first axis;

providing a substrate surface extending between the first opposing lateral members and between the second opposing lateral members;

coupling a plurality of deposition modules to the carriage assembly;

separating each one of the plurality of deposition modules from adjacent ones of the plurality of deposition modules by user-predetermined spacings;

depositing material through a nozzle to form a three dimensional product supported by the substrate surface;

synchronously displacing the plurality of deposition modules a predetermined distance along the first axis;

synchronously displacing the plurality of deposition modules a predetermined distance along the second axis; and

,

synchronously creating a relative displacement between each of the plurality of deposition modules and the substrate surface along a third axis orthogonal to both the first axis and the second axis.

12. The method of claim 11, further comprising releasably engaging the carriage assembly without tools to at least one of the plurality of deposition modules.

13. The method of claim 11, further comprising simultaneously supplying a solid filament material to each one of the nozzles of the deposition modules from a plurality of filament supply modules.

14. The method of claim 11, wherein the carriage assembly comprises at least one guide rod to which at least one of the plurality of deposition modules is configured to releasably attach without tools at a user-predetermined separation between adjacent ones of the plurality of deposition modules.

15. The method of claim 14, further comprising slidably engaging at least one of the deposition modules parallel to the first axis and along the at least one guide rod.

16. The method of claim 11, further comprising releasably engaging each one of the plurality of deposition modules and imparting synchronous displacement in the direction of the first axis.

17. A layer deposition apparatus to form a plurality of 3D products simultaneously, the system comprising:

a deposition frame housing having first opposing lateral members extending orthogonal to a first axis, and second opposing lateral members extending orthogonal to a second axis coplanar with and orthogonal to the first axis;

a carriage assembly extending between the first opposing lateral members and parallel to the first axis;

a substrate surface extending between the first opposing lateral members and between the second opposing lateral members;

a plurality of means for depositing releasably coupled to the carriage assembly, each one of the deposition means separated from adjacent ones of the plurality of deposition means by user-predetermined spacings, and operable to deposit material through a nozzle to form a three dimensional product supported by the substrate surface;

a first axis drive coupled to synchronously displace the plurality of deposition means a predetermined distance along the first axis;

a second axis drive coupled to synchronously displace the plurality of deposition means a predetermined distance along the second axis; and

,

a third axis drive couple to synchronously create a relative displacement between each of the plurality of deposition means and the substrate surface along a third axis orthogonal to both the first axis and the second axis,

wherein the carriage assembly comprises at least one guide rod to which at least one of the plurality of deposition means is configured to releasably attach without tools at a user-predetermined separation between adjacent ones of the plurality of deposition means.

18. The system of claim 17, wherein the deposition frame housing defines a first interior volume through which the substrate surface is vertically displaceable in response to operation of the third axis drive, and further comprising a first modular base frame having third opposing lateral members extending orthogonal to the first axis, and fourth opposing lateral members extending orthogonal to the second axis and defining a second interior volume through which the substrate surface is vertically displaceable in response to operation of the third axis drive.

19. The system of claim 18, wherein the first modular base frame is stackable underneath the deposition frame housing, and defines a second interior volume that substantially aligns with the first interior volume when the deposition frame housing is stacked on the first modular base frame.

20. The system of claim 17, further comprising a plurality of filament supply modules operable to simultaneously supply a solid filament material to each one of the nozzles of the deposition means.