Methods and apparatus for additive manufacturing along user-specified toolpaths

• US 10,286,606 B2
• Filed: 09/15/2015
• Issued: 05/14/2019
• Est. Priority Date: 09/15/2014
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology
• Original Assignee: Massachusetts Institute of Technology
• Inventors: Duro Royo, Jorge, Mogas Soldevila, Laia, Oxman, Neri
• Primary Examiner(s): Thrower, Larry W
• Application Number:
  US14/854,937
• Publication Number:
  US 20160075089A1
• Time in Patent Office: 1,337 Days
• 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 64/393 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

Abstract

One or more input/output devices accept user-inputted path instructions that specify a set of multiple deposition paths for an extruder to travel. An actuator actuates motion of the extruder along a trajectory that includes each of the deposition paths and also includes multiple non-deposition paths. For each deposition path: (a) the user-inputted path instructions specify a thickness of an object; and (b) the extruder extrudes the object in accordance with fabrication instructions computed by a computer based at least in part on the thickness. As the extruder moves over the entire trajectory, the extruder extrudes a set of objects, one object per deposition path. The objects adhere to each other to form an integral 3D structure. In some cases, the objects include functionally graded material.

Claims

1. An apparatus comprising:

(a) one or more I/O devices configured to accept user-inputted path instructions that specify a set of multiple deposition paths for an extruder to travel; and

(b) an actuator configured to actuate physical motion of the extruder along a trajectory that includes each of the deposition paths and also includes multiple non-deposition paths, in such a way that the physical motion of the extruder along the trajectory includes the extruder moving along a deposition path, then along a non-deposition path, and then along another deposition path;

wherein for each respective path in the set of deposition paths

(i) the user-inputted path instructions specify a thickness of an object, and

(ii) the extruder is configured to extrude the object in such a way that (A) the extruder extrudes the object only while the extruder is moving along the respective path, and (B) the extruder extrudes the object in accordance with fabrication instructions computed by a computer based at least in part on the thickness.

2. The apparatus of claim 1, wherein the fabrication instructions specify (i) a pressure in the extruder or (ii) a parameter that is computed by a computer based at least in part on a pressure in the extruder.

3. The apparatus of claim 1, wherein the fabrication instructions specify (i) an extruder speed or (ii) a parameter that is computed by a computer based at least in part on an extruder speed.

4. The apparatus of claim 1, wherein the thickness is a vertical thickness.

5. The apparatus of claim 1, wherein the thickness is a horizontal thickness.

6. The apparatus of claim 1, wherein the extruder is configured in such a way that:

(a) material that exits a nozzle of the extruder comprises a stream of material; and

(b) material properties of the stream vary at different spatial positions of the stream.

7. The apparatus of claim 1, wherein the extruder includes a nozzle that is configured to extrude a stream of material in such a way that the stream has an inner core that consists of a first type of material and has an outer sheath that consists of a second type of material, the first and second types of material being different from each other.

8. The apparatus of claim 1, wherein the extruder includes a set of one or more nozzles configured in such a way that:

(a) material that exits the set of one or more nozzles comprises a first stream and a second stream; and

(b) the first stream has different material properties than the second stream.

9. The apparatus of claim 1, wherein the extruder is configured to extrude a set of multiple objects during the motion along the trajectory, one object per deposition path, in such a way that:

(a) each object, respectively, is an object described in clause (i) of claim 1; and

(b) after the set of objects is extruded, each object in the set of objects adheres to at least one other object in the set of objects in such a way that the set of objects together comprises an integral 3D structure.

10. The apparatus of claim 1, wherein the apparatus is not configured to perform sliced layer-by-layer fabrication.