Extrusion apparatus and method

• US 9,669,582 B2
• Filed: 12/14/2016
• Issued: 06/06/2017
• Est. Priority Date: 02/07/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Larsen, Ty A., Murrish, Richard E.
• Primary Examiner(s): KENNEDY, TIMOTHY J
• Application Number:
  US15/378,126
• Publication Number:
  US 20170120516A1
• Time in Patent Office: 174 Days
• Field of Search: 4253823
• CPC Class Codes: B29C 2948/92571 Position, e.g. linear or angular
• CPC Class Codes: B29C 2948/9258 Velocity
• CPC Class Codes: B29C 2948/92904 Die; Nozzle zone
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/155 Partial coating thereof
• CPC Class Codes: B29C 48/2528 Drive or actuation means for non-plasticising purposes, e.g. dosing unit
• CPC Class Codes: B29C 48/265 Support structures or bases for apparatus, e.g. frames
• 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 48/301 having reciprocating, oscillating or rotating parts
• CPC Class Codes: B29C 48/865 Heating
• 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: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29K 2905/00 Use of metals, their alloys or their compounds, as mould material
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/772 Articles characterised by their shape and not otherwise provided for closed loop B29L2031/709; ring-like B29L2031/7096; corrugated B29L2016/00, flat B29L2007/00; hollow B29L2022/00; screw-threaded B29L2001/00; toothed B29L2031/775; corrugated tubes B29L2023/18
• 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: B33Y 80/00 : Products made by additive manufacturing

Abstract

One aspect of the disclosure relates to an apparatus including an extrusion nozzle. The nozzle includes an inlet end, an outlet end opposite the inlet end and an axis extending between the inlet end and the outlet end. The extrusion nozzle is configured to rotate about the axis. The extrusion nozzle also includes a rotary drive engagement portion between the inlet end and the outlet end. The extrusion nozzle further includes a cavity including an inlet opening at the inlet end and an outlet opening at the outlet end. The inlet opening has a different configuration than the outlet opening.

Claims

1. A method of extruding material, the method comprising:

providing an extrusion nozzle including a rotary drive engagement portion, and a cavity including an inlet end, an inlet opening at the inlet end, an outlet end, an outlet opening at the outlet end, and an external surface extending between the inlet end and the outlet end, wherein

a wall thickness of the extrusion nozzle between the external surface of the extrusion nozzle and a surface of the cavity varies in a plane containing a rotary axis of the extrusion nozzle that extends between the inlet end and the outlet end, and

the cavity has a path that is non-linear; and

moving the extrusion nozzle along a tool path and simultaneously rotating the extrusion nozzle about the rotary axis using the rotary drive engagement portion to maintain the outlet opening of the extrusion nozzle in a predetermined orientation relative to the tool path while extruding the material from the outlet opening.

2. The method of claim 1, further comprising extruding the material as a bead having a generally rectangular cross-section.

3. The method of claim 1, further comprising extruding the material in a direction non-parallel to the rotary axis.

4. The method of claim 1, further comprising extruding the material substantially parallel with the rotary axis.

5. The method of claim 1, further comprising maintaining an outlet pressure at the outlet opening that is at least as high as an inlet pressure at the inlet opening.

6. The method of claim 1, further comprising maintaining a substantially linear pressure gradient between the inlet end and the outlet end.

7. The method of claim 1, further comprising forming the extrusion nozzle by additive metal fabrication.

8. The method of claim 7, wherein the extrusion nozzle is formed by laser sintering.

9. The method of claim 7, wherein the extrusion nozzle is formed as a monolithic member.

10. The method of claim 1, further comprising maintaining the outlet opening tangent to the tool path.

11. The method of claim 1, further comprising moving the extrusion nozzle in a build plane of a three-dimensional printing system.

12. The method of claim 1, further comprising controlling a flow rate of the material extruded from the outlet opening with a controller.

13. A method of extruding material, the method comprising:

providing a three-dimensional printing system including a build platform and a print unit;

providing, in the print unit, an extrusion nozzle including a rotary drive engagement portion, and a cavity including an inlet end, an inlet opening at the inlet end, an outlet end, an outlet opening at the outlet end, and an external surface extending between the inlet end and the outlet end, wherein

a wall thickness of the extrusion nozzle between the external surface of the extrusion nozzle and a surface of the cavity varies in a plane containing a rotary axis of the extrusion nozzle that extends between the inlet end and the outlet end, and

the cavity has a path that is non-linear; and

moving the extrusion nozzle, relative to the build platform, along a tool path and simultaneously rotating the extrusion nozzle about the rotary axis with a rotary drive of the print unit engaged to the rotary drive engagement portion to maintain the outlet opening of the extrusion nozzle in a predetermined orientation relative to the tool path while extruding the material from the outlet opening.

14. The method of claim 13, further comprising extruding the material as a bead having a generally rectangular cross-section.

15. The method of claim 13, further comprising extruding the material in a direction non-parallel to the rotary axis.

16. The method of claim 13, further comprising extruding the material substantially parallel with the rotary axis.

17. The method of claim 13, further comprising maintaining an outlet pressure at the outlet opening that is at least as high as an inlet pressure at the inlet opening.

18. The method of claim 13, further comprising maintaining a substantially linear pressure gradient between the inlet end and the outlet end.

19. The method of claim 13, further comprising maintaining the outlet opening tangent to the tool path.

20. The method of claim 13, further comprising controlling a flow rate of the material extruded from the outlet opening with a controller.