SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER

• US 20170050388A1
• Filed: 07/22/2016
• Published: 02/23/2017
• Est. Priority Date: 08/21/2015
• Status: Abandoned Application

• Current Assignee: Voxel8 Inc. (Kornit Digital Ltd)
• Original Assignee: Voxel8 Inc. (Kornit Digital Ltd)
• Inventors: Minardi, John, Busbee, Travis, Tran, Jonathan, Eskin, Max
• Application Number:
  US15/217,385
• Publication Number:
  US 20170050388A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29B 7/72 Measuring, controlling or regulating
• CPC Class Codes: B29B 7/74 using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
• 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 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/35 Cleaning
• 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
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35134 3-D cad-cam
• CPC Class Codes: G05B 2219/49007 Making, forming 3-D object, model, surface
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A three-dimensional (3D) printer device includes a first extruder configured to deposit a material on a deposition platform, an actuator coupled to at least one of the first extruder or the deposition platform, and a controller coupled to the actuator. The controller is configured to cause the first extruder to deposit a first portion of the material corresponding to a first portion of a physical model. The controller may be configured to cause the first extruder to be cleaned, purged, or both, after the first extruder deposits the first portion of the material. The controller may be configured to cause the first extruder to deposit a second portion of the material after the first extruder is cleaned. The second portion of the material corresponds to a second portion of the physical model.

Claims

1. A three-dimensional (3D) printer device comprising:

a first extruder configured to deposit a material on a deposition platform;

an actuator coupled to at least one of the first extruder or the deposition platform; and

a controller coupled to the actuator, the controller configured to cause the first extruder to deposit a first portion of the material corresponding to a first portion of a physical model, to cause the first extruder to be cleaned, purged, or both, after the first extruder deposits the first portion of the material, and to cause the first extruder to deposit a second portion of the material after the first extruder is cleaned, purged, or both, the second portion of the material corresponding to a second portion of the physical model.

2. The 3D printer device of claim 1, further comprising a memory to store data representing a set of commands, wherein the controller is configured to execute commands of the set of commands to form the physical model.

3. The 3D printer device of claim 1, further comprising a communication interface to receive commands from a computing device, wherein the controller is configured to execute the commands to form the physical model.

4. The 3D printer device of claim 1, further comprising a timer, wherein the controller causes the first extruder to be cleaned, purged, or both, based on the timer satisfying a threshold.

5. The 3D printer device of claim 4, wherein the timer is configured to track time elapsed during deposition of the first portion of the material.

6. The 3D printer device of claim 1, further comprising a material counter configured to track a quantity of the material deposited to form the first portion of the physical model, wherein the controller causes the first extruder to be cleaned, purged, or both, based on a value of the material counter satisfying a threshold.

7. The 3D printer device of claim 1, further comprising a second extruder configured to deposit a second material on the deposition platform.

8. The 3D printer device of claim 7, further comprising a timer associated with the second extruder, wherein the controller causes the first extruder to be cleaned, purged, or both, based on the timer satisfying a threshold.

9. The 3D printer device of claim 8, wherein the timer tracks time since the second extruder was used to deposit the second material.

10. The 3D printer device of claim 8, further comprising:

a first container configured to store a first component of the second material;

a second container configured to store a second component of the second material; and

a mixer configured to mix the first component and the second component to form the second material.

11. The 3D printer device of claim 10, wherein the timer tracks time since mixing the first component and the second component, wherein the controller causes the first extruder to be cleaned, purged, or both, based on the time since mixing satisfying a threshold.

12. The 3D printer device of claim 10, wherein the first component includes a resin and the second component includes a hardening agent.

13. The 3D printer device of claim 7, wherein the controller is configured to cause the second extruder to be cleaned, purged, or both, based on the first extruder being cleaned, purged, or both.

14. The 3D printer device of claim 7, wherein the first extruder comprises filament-feed extruder and the second extruder comprises a paste extruder.

15. The 3D printer device of claim 7, wherein the second extruder comprises filament-feed extruder and the first extruder comprises a paste extruder.

16. The 3D printer device of claim 7, wherein the controller is configured to cause the second extruder to deposit a portion of the second material after the first extruder deposits the first portion of the material and before the first extruder deposits the second portion of the material, wherein the second material is chemically distinct from the material.

17. A three-dimensional (3D) printer device comprising:

a first extruder configured to deposit a first material on a deposition platform;

a second extruder configured to deposit a second material on the deposition platform;

an actuator coupled to the first extruder, the second extruder, the deposition platform, or a combination thereof; and

a controller coupled to the actuator, the controller configured to cause the first extruder to deposit a first portion of the first material corresponding to a first portion of a physical model and to cause the second extruder to be cleaned, purged, or both, after the first extruder deposits the first portion of the first material.

18. The 3D printer device of claim 17, further comprising a memory to store data representing a set of commands, wherein the controller is configured to execute commands of the set of commands to form the physical model.

19. The 3D printer device of claim 17, further comprising a communication interface to receive commands from a computing device, wherein the controller is configured to execute the commands to form the physical model.

20. The 3D printer device of claim 17, further comprising a material counter configured to track a quantity of the first material deposited to form the first portion of the physical model, wherein the controller causes the second extruder to be cleaned, purged, or both, based on a value of the material counter satisfying a threshold.

21. The 3D printer device of claim 17, further comprising a timer, wherein the controller causes the second extruder to be cleaned, purged, or both, based on the timer satisfying a threshold.

22. The 3D printer device of claim 21, wherein the timer is configured to track time elapsed during deposition of the first portion of the first material.

23. The 3D printer device of claim 21, wherein the timer tracks time since the second extruder was used to deposit the second material.

24. The 3D printer device of claim 21, further comprising:

a first container configured to store a first component of the second material;

a second container configured to store a second component of the second material; and

a mixer configured to mix the first component and the second component to form the second material.

25. The 3D printer device of claim 24, wherein the timer tracks time since mixing the first component and the second component, wherein the controller causes the second extruder to be cleaned, purged, or both, based on the time since mixing satisfying a threshold.

26. The 3D printer device of claim 24, wherein the first component include a resin and the second component includes a hardening agent.

27. The 3D printer device of claim 17, wherein the controller is configured to cause the first extruder to be cleaned, purged, or both, based on the second extruder being cleaned.

28. The 3D printer device of claim 17, wherein the first extruder comprises filament-feed extruder and the second extruder comprises a paste extruder.

29. The 3D printer device of claim 17, wherein the second extruder comprises filament-feed extruder and the first extruder comprises a paste extruder.

30. The 3D printer device of claim 17, wherein the controller is configured to cause the second extruder to deposit a portion of the second material after the first extruder deposits the portion of the first material.

31. The 3D printer device of claim 17, wherein the controller is configured to perform a test print using the first extruder and the second extruder to calibrate relative positions of the first extruder and the second extruder.

32. A method comprising:

depositing, using a first extruder of a three-dimensional (3D) printer device, a first portion of a first material corresponding to a first portion of a physical model of an object;

after depositing the first portion of the first material, cleaning the first extruder, purging the first extruder, or cleaning and purging the first extruder; and

after cleaning the first extruder, purging the first extruder, or cleaning and purging the first extruder, depositing, using the first extruder, a second portion of the first material, the second portion of the first material corresponding to a second portion of the physical model.

33. The method of claim 32, further comprising storing data representing a set of commands to form the physical model at a memory of the 3D printer device.

34. The method of claim 32, further comprising receiving data representing a set of commands to form the physical model via a communication interface of the 3D printer device.

35. The method of claim 32, further comprising tracking a quantity of the first material deposited to form the first portion of the physical model, wherein the first extruder is cleaned, purged, or both, based on the quantity of the first material deposited satisfying a threshold.

36. The method of claim 32, further comprising tracking a deposition time associated with forming the first portion of the physical model, wherein the first extruder is cleaned, purged, or both, based on the deposition time satisfying a threshold.

37. The method of claim 32, further comprising tracking downtime of a second extruder of the 3D printer device, wherein the first extruder is cleaned, purged, or both, based on the downtime of the second extruder satisfying a threshold.

38. The method of claim 32, further comprising:

mixing two or more components to form the first material; and

tracking a time since mixing, wherein the first extruder is cleaned, purged, or both, based on the time since mixing satisfying a threshold.

39. The method of claim 38, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

40. The method of claim 38, wherein mixing the two or more components includes:

dispensing a resin from a first container of the 3D printer device into a mixer of the 3D printer device;

dispensing a hardening agent from a second container of the 3D printer device into the mixer; and

mixing the resin and the hardening agent in the mixer, wherein the mixer is in fluid communication with the first extruder.

41. The method of claim 32, further comprising:

mixing two or more components to form a second material associated with a second extruder of the 3D printer device; and

tracking a time since mixing, wherein the first extruder is cleaned, purged, or both, based on the time since mixing satisfying a threshold.

42. The method of claim 41, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

43. The method of claim 41, further comprising cleaning the second extruder after depositing the first portion of the first material and before depositing the second portion of the first material.

44. The method of claim 41, wherein the first extruder comprises filament-feed extruder and the second extruder comprises a paste extruder.

45. The method of claim 32, further comprising, after depositing the first portion of the first material and before depositing the second portion of the first material depositing a second material, using a second extruder of the 3D printer device, wherein the second material is chemically distinct from the first material.

46. The method of claim 32, further comprising, after depositing the first portion of the first material and before depositing the second portion of the first material, cleaning a second extruder, purging the second extruder, or cleaning and purging the second extruder.

47. A method comprising:

depositing, using a first extruder of a three-dimensional (3D) printer device, a portion of a first material to form a first portion of a physical model; and

after depositing the portion of the first material, cleaning a second extruder of the 3D printer device, purging the second extruder, or cleaning and purging the second extruder.

48. The method of claim 47, further comprising storing data representing a set of commands to form the physical model at a memory of the 3D printer device.

49. The method of claim 47, further comprising receiving data representing a set of commands to form the physical model via a communication interface of the 3D printer device.

50. The method of claim 47, further comprising tracking a quantity of the first material deposited to form the first portion of the physical model, wherein the second extruder is cleaned, purged, or both, based on the quantity of the first material deposited satisfying a threshold.

51. The method of claim 47, further comprising tracking a deposition time associated with forming the first portion of the physical model, wherein the second extruder is cleaned, purged, or both, based on the deposition time satisfying a threshold.

52. The method of claim 47, further comprising tracking downtime of the second extruder, wherein the second extruder is cleaned, purged, or both, based on the downtime of the second extruder satisfying a threshold.

53. The method of claim 47, further comprising:

mixing two or more components to form the first material; and

tracking a time since mixing, wherein the second extruder is cleaned, purged, or both, based on the time since mixing satisfying a threshold.

54. The method of claim 53, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

55. The method of claim 47, further comprising:

mixing two or more components to form a second material associated with the second extruder; and

tracking a time since mixing, wherein the second extruder is cleaned, purged, or both, based on the time since mixing satisfying a threshold.

56. The method of claim 55, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

57. The method of claim 55, further comprising after depositing the portion of the first material and before depositing a second portion of the first material, cleaning the first extruder, purging the first extruder, or cleaning and purging the first extruder.

58. The method of claim 47, further comprising depositing, using the second extruder of the 3D printer device, a second material after depositing the portion of the first material and before depositing a second portion of the first material, wherein the second material is chemically distinct from the first material.

59. The method of claim 47, wherein the first extruder comprises filament-feed extruder and the second extruder comprises a paste extruder.

60. The method of claim 47, wherein the second extruder comprises filament-feed extruder and the first extruder comprises a paste extruder.

61. A method comprising:

obtaining model data representing a three-dimensional (3D) model of an object; and

processing the model data to generate a set of commands to direct a 3D printer to extrude a material to form a physical model associated with the object, the set of commands executable to cause an extruder of the 3D printer to deposit a first portion of the material corresponding to a first portion of the physical model, to clean, to purge, or to clean and purge the extruder after depositing the first portion of the material, and to deposit a second portion of the material after cleaning the extruder, purging the extruder, or cleaning and purging the extruder, the second portion of the material corresponding to a second portion of the physical model.

62. The method of claim 61, further comprising storing data representing the set of commands.

63. The method of claim 61, further comprising sending data representing the set of commands to the 3D printer via a communication interface.

64. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to track a quantity of the material deposited to form the first portion of the physical model, and to cause the 3D printer to clean, to purge, or to clean and purge the extruder based on the quantity of the material deposited satisfying a threshold.

65. The method of claim 61, wherein generating the set of commands includes determining a quantity of the material to be deposited to form the first portion of the physical model and including a cleaning sequence in the set of commands based on the quantity of the material deposited satisfying a threshold.

66. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to track a deposition time associated with forming the first portion of the physical model and to cause the 3D printer to clean, to purge, or to clean and purge the extruder based on the deposition time satisfying a threshold.

67. The method of claim 61, wherein generating the set of commands includes determining a deposition time associated with forming the first portion of the physical model and including a cleaning sequence in the set of commands based on the deposition time satisfying a threshold.

68. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to track downtime of a second extruder and to clean, to purge, or to clean and purge the extruder based on the downtime of the second extruder satisfying a threshold.

69. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to mix two or more components to form the material.

70. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to mix two or more components to form the material, to track a time since mixing, and to clean, to purge, or to clean and purge the extruder based on the time since mixing satisfying a threshold.

71. The method of claim 70, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

72. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to mix two or more components to form a second material associated with a second extruder of the 3D printer, to track a time since mixing, and to clean, to purge, or to clean and purge the extruder based on the time since mixing satisfying a threshold.

73. The method of claim 72, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

74. The method of claim 72, wherein the set of commands is executable to cause the 3D printer to clean, to purge, or to clean and purge the second extruder after depositing the first portion of the material and before depositing the second portion of the material.

75. The method of claim 72, wherein the extruder comprises filament-feed extruder and the second extruder comprises a paste extruder.

76. The method of claim 61, wherein the set of commands is executable to cause the 3D printer to deposit a second material after depositing the first portion of the material and before depositing the second portion of the material, wherein the second material is chemically distinct from the material.

77. The method of claim 61, wherein the 3D model includes a first model portion representing a matrix material and a second model portion representing a filler material, and wherein processing the model data includes:

identifying a first region of the 3D model that includes the matrix material and a second region of the 3D model that includes the filler material, wherein at least a portion of the second region is enveloped by at least a portion of the first region in the 3D model; and

automatically modifying the model data to omit at least a portion of the matrix material from the first region of the 3D model.

78. The method of claim 77, wherein dimensions of the portion of the matrix material omitted from the first region of the 3D model are determined based on physical dimensions of a second extruder associated with the filler material.

79. The method of claim 61, wherein the set of commands includes G-code commands.

80. A method comprising:

obtaining model data representing a three-dimensional (3D) model of an object; and

processing the model data to generate a set of commands to direct a 3D printer to extrude one or more materials to form a physical model associated with the object, the set of commands executable to cause a first extruder of the 3D printer to deposit a portion of a first material to form a first portion of the physical model and to, after depositing the portion of the first material, clean a second extruder of the 3D printer, purge the second extruder, or clean and purge the second extruder.

81. The method of claim 80, further comprising storing data representing the set of commands.

82. The method of claim 80, further comprising sending data representing the set of commands to the 3D printer via a communication interface.

83. The method of claim 80, wherein the set of commands is executable to cause the 3D printer to track a quantity of the first material deposited to form the first portion of the physical model, and to cause the 3D printer to clean, to purge, or to clean and purge the second extruder based on the quantity of the first material deposited satisfying a threshold.

84. The method of claim 80, wherein generating the set of commands includes determining a quantity of the first material to be deposited to form the first portion of the physical model and including a cleaning sequence to clean, to purge, or to clean and purge the second extruder in the set of commands based on the quantity of the first material deposited satisfying a threshold.

85. The method of claim 80, wherein the set of commands is executable to cause the 3D printer to track a deposition time associated with forming the first portion of the physical model and to cause the 3D printer to clean, to purge, or to clean and purge the second extruder based on the deposition time satisfying a threshold.

86. The method of claim 80, wherein generating the set of commands includes determining a deposition time associated with forming the first portion of the physical model and including a cleaning sequence to clean, to purge, or to clean and purge the second extruder in the set of commands based on the deposition time satisfying a threshold.

87. The method of claim 80, wherein the set of commands is executable to cause the 3D printer to track downtime of the second extruder and to clean, to purge, or to clean and purge the second extruder based on the downtime of the second extruder satisfying a threshold.

88. The method of claim 80, wherein the set of commands is executable to cause the 3D printer to mix two or more components to form the first material.

89. The method of claim 80, wherein the set of commands is executable to cause the 3D printer to mix two or more components to form the first material, to track a time since mixing, and to clean, to purge, or to clean and purge the second extruder based on the time since mixing satisfying a threshold.

90. The method of claim 89, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

91. The method of claim 80, wherein the set of commands is executable to cause the 3D printer to mix two or more components to form a second material associated with the second extruder, to track a time since mixing, and to clean, to purge, or to clean and purge the second extruder based on the time since mixing satisfying a threshold.

92. The method of claim 91, wherein the two or more components include a resin and a hardening agent, wherein the two or more components begin to cure upon mixing, and wherein the threshold is based on cure time of a mixture including the two or more components.

93. The method of claim 91, wherein the set of commands is executable to cause the 3D printer to clean, to purge, or to clean and purge the first extruder after depositing the portion of the first material and before depositing a second portion of the first material.

94. The method of claim 80, wherein the set of commands are further executable to cause the 3D printer deposit a second material after depositing the portion of the first material and before depositing a second portion of the first material, wherein the second material is chemically distinct from the first material.

95. The method of claim 80, wherein the 3D model includes a first model portion representing a matrix material and a second model portion representing a filler material, and wherein processing the model data includes:

identifying a first region of the 3D model that includes the matrix material and a second region of the 3D model that includes the filler material, wherein at least a portion of the second region is enveloped by at least a portion of the first region in the 3D model; and

automatically modifying the model data to omit at least a portion of the matrix material from the first region of the 3D model.

96. The method of claim 95, wherein dimensions of the portion of the matrix material omitted from the first region of the 3D model are determined based on physical dimensions of an extruder associated with the filler material, wherein the extruder associated with the filler material corresponds to the first extruder or corresponds to the second extruder.

97. The method of claim 80, wherein the first extruder comprises filament-feed extruder and the second extruder comprises a paste extruder.

98. The method of claim 80, wherein the set of commands includes G-code commands.