3D printer with native spherical control

• US 9,339,975 B2
• Filed: 12/31/2013
• Issued: 05/17/2016
• Est. Priority Date: 12/31/2013
• Status: Expired due to Fees

• Current Assignee: Feng TAY Enterprises Company Limited
• Original Assignee: Nike, Inc.
• Inventors: Molinari, Arthur, Bender, Aaron
• Primary Examiner(s): Gupta, Yogendra
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US14/144,909
• Publication Number:
  US 20150183167A1
• Time in Patent Office: 868 Days
• Field of Search: 425/60, 425/385, 219/76.12, 219/76.14
• 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 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/241 for rotary motion
• CPC Class Codes: B29C 64/336 of two or more materials
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• 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

A three dimensional printer includes a work surface, an arcuate track disposed within in a track plane that is orthogonal to the work surface, a carriage slidably disposed on the track and translatable relative thereto, and a print head supported by the carriage. The track has a constant radius of curvature extending from a point on the work surface. The print head is translatable in a radial direction relative to the track, and includes a nozzle defining a print orifice, a mixing cavity disposed within the nozzle and in fluid communication with the orifice, and both a first and second filament feeder, each configured to controllably advance a respective filament into the mixing cavity at a respective feed rate. The print head further includes a heating element in thermal communication with the mixing cavity and configured to melt each of the first filament and the second filament.

Claims

1. A three dimensional printer comprising:

a work surface;

an arcuate track disposed within a track plane that is orthogonal to the work surface, the track having a constant radius of curvature extending from a point on the work surface;

a motor coupled with the arcuate track and configured to controllably rotate the track plane about an axis extending normal to the work surface;

a carriage slidably disposed on the track and translatable relative thereto;

a print head supported by the carriage and translatable in a radial direction relative to the track; and

wherein the print head is configured to receive a solid thermoplastic material, melt the thermoplastic material, and deposit the molten thermoplastic material on a substrate.

2. The printer of claim 1, wherein the print head includes:

a nozzle defining a print orifice;

a mixing cavity disposed within the nozzle and in fluid communication with the orifice;

a first filament feeder configured to controllably advance a first thermoplastic filament into the mixing cavity at a first feed rate;

a second filament feeder configured to controllably advance a second filament into the mixing cavity at a second feed rate; and

a heating element in thermal communication with the mixing cavity and configured to melt each of the first filament and the second filament.

3. The printer of claim 2, further comprising a controller configured to control the motion of the print head relative to the work surface in three dimensions, and to control the respective feed rate of each of the first and second filament feeders.

4. The printer of claim 3, wherein the controller is configured to control the motion of the print head relative to the work surface by:

specifying a radial distance, a polar angle, and an azimuth angle for the print head relative to the work surface;

controlling the motion of the carriage along the track to achieve the azimuth angle;

controlling the motion of the print head relative to the carriage to achieve the radial distance; and

controlling the relative rotation between the arcuate track and the work surface to achieve the polar angle.

5. The printer of claim 2, wherein each of the first and second filament feeders includes a respective pair of feeder wheels configured to rotate in opposing directions to advance the respective filament.

6. The printer of claim 2, wherein the nozzle is configured to expel a molten material through the orifice, and wherein the molten material is a mixture of the first filament and the second filament.

7. The printer of claim 1, further comprising a turntable defining the work surface;

and

wherein the turntable is configured to controllably rotate about an axis normal to the work surface.

8. A three dimensional printer comprising:

a work surface;

an arcuate track disposed within a track plane that is orthogonal to the work surface, the track having a constant radius of curvature extending from a point on the work surface;

a motor coupled with the arcuate track and configured to controllably rotate the track plane about an axis extending normal to the work surface;

a carriage slidably disposed on the track and translatable relative thereto;

a print head supported by the carriage and translatable in a radial direction relative to the track, the print head including;

a nozzle defining a print orifice;

a mixing cavity disposed within the nozzle and in fluid communication with the orifice;

a first filament feeder configured to controllably advance a first filament into the mixing cavity at a first feed rate;

a second filament feeder configured to controllably advance a second filament into the mixing cavity at a second feed rate; and

a heating element in thermal communication with the mixing cavity and configured to melt each of the first filament and the second filament.

9. The printer of claim 8, further comprising a turntable defining the work surface;

and

wherein the turntable is configured to controllably rotate about an axis normal to the work surface.

10. The printer of claim 8, further comprising a controller configured to control the motion of the print head relative to the work surface in three dimensions, and to control the respective feed rate of each of the first and second filament feeders.

11. The printer of claim 10, wherein the controller is configured to control the motion of the print head relative to the work surface by:

specifying a radial distance, a polar angle, and an azimuth angle for the print head relative to the work surface;

controlling the motion of the carriage along the track to achieve the azimuth angle;

controlling the motion of the print head relative to the carriage to achieve the radial distance; and

controlling the relative rotation between the arcuate track and the work surface to achieve the polar angle.

12. The printer of claim 8, wherein each of the first and second filament feeders includes a respective pair of feeder wheels configured to rotate in opposing directions to advance the respective filament.

13. The printer of claim 8, wherein the nozzle is configured to expel a molten material through the orifice, and wherein the molten material is a mixture of the first filament and the second filament.

14. The printer of claim 8, wherein the heating element is a wire coiled about the mixing cavity.