3D PRINTER

• US 20160236407A1
• Filed: 08/31/2015
• Published: 08/18/2016
• Est. Priority Date: 02/17/2015
• Status: Abandoned Application

• Current Assignee: David Souza Jones, Michael Daniel Armani
• Original Assignee: David Souza Jones, Michael Daniel Armani
• Inventors: Jones, David Souza, Armani, Michael Daniel
• Application Number:
  US14/840,314
• Publication Number:
  US 20160236407A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• 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: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B29K 2879/00 Use of polymers having nitrogen, with or without oxygen, or carbon only, in the main chain not provided for in groups B29K2861/00 - B29K2877/00, as mould material
• CPC Class Codes: B29K 2883/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material
• CPC Class Codes: B29K 2885/00 Use of polymers having other elements than silicon, sulfur, nitrogen, oxygen, and carbon in the main chain, as mould material
• CPC Class Codes: B29K 2909/02 Ceramics
• CPC Class Codes: B29K 2909/08 Glass
• CPC Class Codes: B29K 2995/0037 Other properties
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: G05B 19/402 characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position G05B19/19 takes precedence

Abstract

A 3D printer has a casing, a nozzle for printing, an extruder, a heating element, and a print bed. The casing encloses a region above and around the print bed to form a printing zone. The apparatus has a plurality of micro motors for controlling movement of the nozzle during printing. Further, the 3D printer has safer components as compared with the prior art, ideal for use in home and education situations, and includes a rounded edge design of the printer, an improved small and enclosed area of the printer heating element, and a lower power system, reducing the risk of electrical shock.

Claims

1. A 3D printer apparatus, comprising:

a casing;

a nozzle for printing, an extruder, and a print bed;

said casing enclosing a region above and around said print bed to form a printing zone;

a heating element; and

a plurality of micro motors for controlling movement of said nozzle during printing.

2. The 3D printer apparatus of claim 1, wherein space limits of extruder motion in X, Y, and Z directions are approximately 50-80 mm smaller than the total external outer dimensions of the 3D printer frame.

3. The 3D printer apparatus of claim 1, further comprising a motor system which includes a Y gantry motor system which conceals components of said motor system.

4. The 3D printer apparatus of claim 1, further comprising a Y motion split pulley adapted to reduce backlash and friction.

5. The 3D printer apparatus of claim 1, further comprising a Y motion slider adapted to reduce friction and adapted to enable high manufacturing tolerances.

6. The 3D printer apparatus of claim 1, further comprising bearings, and wherein said casing has a high-tolerance injection moldable design enabling interference fitting of said bearings.

7. The 3D printer apparatus of claim 1, further comprising a gantry Z threaded rod motion system with a plurality of rods having diameters in a range of 3.0 to 5.0 mm, and having threads ranging from 20 to 32 threads per inch;

wherein said plurality of rods includes at least three threaded rods.

8. The 3D printer apparatus of claim 1, further comprising an ultra-compact extruder assembly mounted in said extruder housing.

9. The 3D printer apparatus of claim 1, further comprising a low power heating element.

10. The 3D printer apparatus of claim 1, which uses 5 to 20 watts of power during operation, and further comprises a heating element operating at a power of 5 to 15 watts and motors operating at a power of 1 to 5 watts each;

and having a zero power 3D printer print bed solution for adhering to ABS and similar plastics as the print bed.

11. A nozzle for use in 3D printing, comprising:

a nozzle body;

a nozzle hole;

said nozzle body having a thermal buffering region having an inner diameter and an outer diameter; and

a thermal break region.

12. A nozzle for use in 3D printing as claimed in claim 11, further comprising an insert member composed of PTFE tubing.

13. A nozzle for use in 3D printing as claimed in claim 11, wherein said nozzle body has a thermal conductivity in a range of 5 to 30 W/mK, a nozzle hole size in a range of 0.25 to 1.0 mm, said inner diameter of said thermal buffering region having a thickness in a range of 2.5 to 3.5 mm, and said outer diameter of said thermal buffering region having a thickness in a range of 3.8 to 5.0 mm.

14. A 3D printer apparatus, comprising:

a casing;

a nozzle for printing and a print bed disposed within said casing;

said casing enclosing a region above and around said print bed to form a printing zone;

an extruder housing;

a printer heating element disposed within said extruder housing;

said printer heating element being adapted for use as a temperature sensor for preventing thermal runaways; and

a plurality of micro motors for controlling movement of said nozzle during printing.

15. A 3D printer apparatus as claimed in claim 14, wherein each of said plurality of micro motors has a resistance in a range of 0.5 to 30 ohms.

16. A 3D printer apparatus as claimed in claim 14, further comprising a motor control system for controlling said plurality of micro motors to maintain their temperature by running them at high speeds, and said motor control system controlling said plurality of micro motors using current control only at low speeds.

17. A 3D printer apparatus as claimed in claim 14, further comprising a motor control system having a backlash control means, wherein said backlash control means controls system axes backlash by compensating with software and includes an autocalibration subroutine that uses at least one of vibration sensing and acceleration sensing to measure an amount of backlash, and

for mproving print quality by actively monitoring backlash properties.

18. A 3D printer apparatus as claimed in claim 14, further comprising a print bed having a Zero Power Print Bed Solution, wherein said print bed is adapted to bond models semi-reversibly, said print bed being composed of ABS with a carefully calibrated bed level and starting extrusion layer height when modeling with ABS.

19. A 3D printer apparatus as claimed in claim 18, wherein said print bed includes particles composed of at least one of TiO2 and glass fiber, for reducing adhesion between said print bed and the model.