Fixed printhead fused filament fabrication printer and method

• US 8,944,802 B2
• Filed: 01/25/2013
• Issued: 02/03/2015
• Est. Priority Date: 01/25/2013
• Status: Expired due to Fees

• Current Assignee: Radiant Fabrication, Inc.
• Original Assignee: Radiant Fabrication, Inc.
• Inventors: Patterson, Nathan James, Harris, Kevin Lee
• Primary Examiner(s): Hindenlang, Alison
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US13/750,731
• Publication Number:
  US 20140210137A1
• Time in Patent Office: 739 Days
• Field of Search: 425/174, 425/375, 425/190, 264/308, 700/119
• US Class Current: 425/375
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/266 Means for allowing relative movements between the apparatus parts, e.g. for twisting the extruded article or for moving the die along a surface to be coated
• 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 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof

Abstract

A fused filament fabrication printer uses a plurality of fixed printing heads mounted to a structure over a build platform on which the model is built by constructing each layer of the model as the build platform is indexed through a multiplicity of successive print planes. The build platform may be in the form of a circular disk mounted for rotation about a z-axis and for linear motion along the z-axis between successive print planes, and for linear motion along a y-axis which is a selected radial direction perpendicular to the z-axis. Because the printheads are fixed, multiple printheads are easily affixed with respect to the build platform along the same radial line defining the y-axis transverse to the selected radial direction along which the build platform moves.

Claims

1. A fused filament fabrication printer comprising:

a frame;

at least one printhead fixedly mounted to the frame;

a first carriage mounted to the frame for vertical motion;

a second carriage mounted to the first carriage for horizontal motion;

a build platform, having a start-print surface, the build platform rotatably mounted to the second carriage, and positioned opposite the printhead(s), so that as the build platform rotates and moves in a horizontal direction opposite the printhead(s), the printhead(s) scan in a print plane parallel to the start-print surface;

wherein the first carriage mounted to the frame for vertical motion is arranged to move away from the printhead(s) so that the start-print plane is moved away from the printhead(s).

2. The fused filament fabrication printer of claim 1 further comprising a plurality of printheads mounted to the frame along lines extending through an axis of rotation defined by rotary mounting of the build platform.

3. The fused filament fabrication printer of claim 2 wherein the plurality of printheads mounted to the frame are on a line extending in a horizontal direction defined by the second carriage mounting for horizontal motion.

4. The fused filament fabrication printer of claim 1 further comprising:

a first motor mounted to the frame and connected in driving relation to the first carriage to cause the first carriage to move in a vertical direction;

a second motor mounted to the first carriage and connected in driving relation to the second carriage to cause the second carriage to move in a horizontal direction;

a third motor mounted to the second carriage and connected in driving relation to the build platform to cause the build platform and the start-print surface to rotate on the second carriage.

5. The fused filament fabrication printer of claim 4 wherein the first motor, the second motor, and the third motor are stepper motors, so that motion of the build platform with respect to the printhead(s) is by indexing by selected interval with respect to the printhead(s).

6. The fused filament fabrication printer of claim 4 wherein the first motor and the second motor are stepper motors and the third motor is a direct current motor so that motion of the build platform with respect to the printhead(s) is by indexing by selected interval with respect to the printhead(s) in the vertical and horizontal directions, and continuously in rotation with respect to the printhead(s).

7. The fused filament fabrication printer of claim 4 further comprising:

two vertical ways mounted spaced apart to the frame, and wherein the first carriage has two spaced apart vertical bearings which slide on the two vertical ways and position the second carriage between the two spaced apart vertical bearings;

wherein the first motor is connected in driving relation to a vertical machine screw mounted for rotation to the frame, wherein the first carriage is threadedly engaged with the machine screw so as to translate the first carriage in the vertical direction.

8. The fused filament fabrication printer of claim 4 further comprising:

at least one horizontal way mounted to the first carriage, wherein the second carriage has at least one horizontal bearing which slides on the at least one horizontal way; and

wherein the second motor mounted to the first carriage and is connected in driving relation a horizontal machine screw mounted for rotation to the first carriage, wherein the build platform is threadedly engaged with the machine screw for translate the build platform in the horizontal direction, when the horizontal machine screw is rotated.

9. The fused filament fabrication printer of claim 4 further comprising a motor mounting bracket mounted to the second carriage, wherein the third motor is mounted to the bracket and has a drive shaft extending parallel to a z-axis, the drive shaft having a tooth drive pulley and connected in driving relation to a sprocket by a timing belt, the build platform being connected to the sprocket to be driven in rotation with the sprocket.

10. A fused filament fabrication printer comprising:

a frame;

a first carriage mounted to the frame for vertical motion;

a second carriage mounted to the first carriage for horizontal motion;

a build platform having a surface, the build platform rotatably mounted to the second carriage, so that rotation of the build platform defines an axis of rotation;

a plurality of printheads mounted to the frame along lines extending through the axis of rotation defined by the build platform;

wherein the build platform is positioned opposite the printheads, so that as the build platform rotates and moves in a horizontal direction opposite the printheads, so that the printheads can print in a print plane parallel to the surface of the build platform, as the build platform is moved relative to the printheads;

wherein the first carriage mounted to the frame for vertical motion is arranged to move away from the printheads so that the print plane is moved away from the printheads.

11. The fused filament fabrication printer of claim 10 wherein the plurality of printheads mounted to the frame are on a line extending in a horizontal direction defined by the first carriage mounting for horizontal motion.

12. The fused filament fabrication printer of claim 10 wherein the build platform has a build area on which an object can be printed which is defined by a radius extending out from the axis of rotation;

and

wherein motion of the second carriage on the first carriage is limited to a travel length less than the radius defining the build area.

13. The fused filament fabrication printer of claim 10 wherein the printheads are adjustably mounted to the frame for positioning between operation cycles of the fused filament fabrication printer.

14. The fused filament fabrication printer of claim 10 wherein the printheads are mounted to the frame on opposite sides of the axis of rotation.

15. The fused filament fabrication printer of claim 14 wherein the printheads are each connected to a supply of material for extruding onto the build platform, and wherein the printheads mounted to the frame on opposite sides of the axis of rotation are connected to supplies of different materials for extruding onto the build platform.