Print head assembly and print head for use in fused deposition modeling system

• US 9,168,685 B2
• Filed: 01/03/2014
• Issued: 10/27/2015
• Est. Priority Date: 12/22/2010
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Swanson, William J., Batchedler, J. Samuel, Johnson, Kevin C., Hjelsand, Timothy A., Comb, James W.
• Primary Examiner(s): Johnson, Christina
• Assistant Examiner(s): LIU, XUE H
• Application Number:
  US14/147,073
• Publication Number:
  US 20140120194A1
• Time in Patent Office: 662 Days
• Field of Search: 425/150
• US Class Current: 1/1
• CPC Class Codes: B29C 41/52 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: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/25 Housings, e.g. machine housings
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor

Abstract

A print head assembly that includes a print head carriage and multiple, replaceable print heads that are configured to be removably retained in receptacles of the print head carriage. The print heads each include a cartridge assembly and a liquefier pump assembly retained by the cartridge assembly.

Claims

1. A print head assembly for use in an additive manufacturing system, the print head assembly comprising:

a carriage frame retained by a gantry mechanism of the additive manufacturing system that is configured to move the carriage frame substantially in a first plane, wherein the carriage frame is configured to operably receive a plurality of individually replaceable print heads;

a control board retained by the carriage frame;

one or more pivot connections retained by the carriage frame, and configured to;

restrict movement of each received print head relative to the carriage frame in directions parallel to the first plane; and

permit pivoting movements of each received print head relative to the carriage frame in directions substantially parallel to a second plane that is orthogonal to the first plane;

a toggle mechanism for each received print head configured to receive electrical power from the control board to controllably move the received print head relative to the carriage frame with the pivoting movements; and

one or more hard stops configured to limit ranges of the pivoting movements of each received print head.

2. The print head assembly of claim 1, and further comprising one or more optical encoder assemblies configured to operably measure positions of the received print heads relative to the carriage frame in the directions outside of the first plane, and to send information of the measured positions to the control board.

3. The print head assembly of claim 1, wherein the one or more pivot connections are further configured to prevent roll and yaw movements of each received print head relative to the carriage frame in the first plane.

4. The print head assembly of claim 1, wherein the pivoting movements of each received print head comprise seesaw-based pivoting movements or lever-based pivoting movements.

5. The print head assembly of claim 1, wherein the toggle mechanism is configured to controllably move each received print head relative to the carriage frame in a manner that is independent of the controlled movements of other received print heads.

6. The print head assembly of claim 1, wherein each toggle mechanism comprises a voice coil retained by the carriage frame.

7. A print head assembly for use in an additive manufacturing system, the print head assembly comprising:

a carriage frame configured to be retained by a gantry mechanism of the additive manufacturing system to move the carriage frame substantially in an x-y plane of an x-y-z Cartesian coordinate system, wherein the carriage frame is also configured to operably receive a plurality of individually replaceable print heads;

one or more pivot connections retained by the carriage frame, and configured to;

restrict movement of each received print head relative to the carriage frame in directions parallel to the x-y plane; and

permit pivoting movements of each received print head relative to the carriage frame in directions parallel to a y-z plane;

a toggle mechanism for each received print head, wherein each toggle mechanism is configured to controllably move the received print head relative to the carriage frame with the pivoting movements in a manner that is independent of the controlled movements of other received print heads; and

one or more hard stops configured to limit ranges of the pivoting movements of each received print head.

8. The print head assembly of claim 7, and further comprising one or more optical encoder assemblies configured to operably measure positions of the received print heads relative to the carriage frame.

9. The print head assembly of claim 7, wherein the one or more pivot connections are further configured to prevent roll and yaw movements of each received print head relative to the carriage frame in the x-y plane.

10. The print head assembly of claim 7, wherein each toggle mechanism comprises a voice coil retained by the carriage frame.

11. The print head assembly of claim 7, wherein the pivoting movements of each received print head comprise seesaw-based pivoting movements or lever-based pivoting movements.

12. The print head assembly of claim 7, and further comprising a control board secured to the carriage frame and configured to supply electrical power to each toggle mechanism.

13. The print head assembly of claim 12, and further comprising one or more electrical connections configured to electrically connect the received print heads to the control board.

14. The print head assembly of claim 7, and further comprising one or more cooling units configured to direct air into a cartridge assembly of each of the received print heads.

15. A print head assembly for use in an additive manufacturing system, the print head assembly comprising:

a carriage frame configured to be retained by a gantry mechanism of the additive manufacturing system to move the carriage frame substantially in a plane;

a first print head having a first liquefier tip, and configured to be pivotally connected to the carriage frame in a manner that restricts movement of the first print head relative to the carriage frame in directions parallel to the plane, and that permits pivoting movements of the first print head relative to the carriage frame;

a second print head having a second liquefier tip, and configured to be pivotally connected to the carriage frame in a manner that restricts movement of the second print head relative to the carriage frame in directions parallel to the plane, and that permits pivoting movements of the second print head relative to the carriage frame;

a first voice coil mechanism configured to controllably raise and lower the first liquefier tip of the first print head relative to the plane with the pivoting movements;

a second voice coil mechanism configured to controllably raise and lower the second liquefier tip of the second print head relative to the plane with the pivoting movements in a manner that is independent of the pivoting movements of the first print head; and

one or more hard stops configured to limit ranges of the pivoting movements of the first and second received print heads.

16. The print head assembly of claim 15, and further comprising one or more sensor assemblies configured to operably measure positions of the first and second print heads relative to the carriage frame.

17. The print head assembly of claim 15, and further comprising a control board secured to the carriage frame and configured to supply electrical power to the first and second voice coil mechanisms.

18. The print head assembly of claim 15, wherein the first print head is further configured to be pivotally connected to the carriage frame such that roll and yaw movements of the first print head relative to the carriage frame in the first plane are prevented.

19. The print head assembly of claim 15, wherein the first and second voice coil mechanisms each comprise a voice coil secured to the carriage frame.

20. The print head assembly of claim 15, wherein the pivoting movements of first and second print heads each comprise seesaw-based pivoting movements or lever-based pivoting movements.