Three-dimensional printer tool systems

• US 10,525,691 B2
• Filed: 10/24/2018
• Issued: 01/07/2020
• Est. Priority Date: 11/15/2013
• Status: Active Grant

• Current Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Original Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Inventors: Schmehl, Peter Joseph, Kemperle, Aljosa, Schmehl, Stewart
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Nguyen, Thu Khanh T
• Application Number:
  US16/169,982
• Publication Number:
  US 20190061334A1
• Time in Patent Office: 440 Days
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• 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 48/2888 in band or in strip form, e.g. rubber strips
• CPC Class Codes: B29C 48/832 Heating
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 64/30 Auxiliary operations or equipment
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29L 2009/00 Layered products
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling

Abstract

An extrusion head or other similar tool head of a three-dimensional printer is slidably mounted along a feedpath of build material so that the extruder can move into and out of contact with a build surface according to whether build material is being extruded. The extrusion head may be spring-biased forward along a feedpath to rest in a downward position, or the extrusion head may be spring-biased against the forward feedpath so that the extruder remains above the build surface in the absence of applied forces, and then moves downward into a position for extrusion when build material is fed into the extruder.

Claims

1. A device comprising:

an extruder configured to removably and replaceably couple to a three- dimensional printer in a predetermined alignment to an axis of a feedpath for a filament of build material driven by a drive assembly of the three-dimensional printer; and

an extrusion head including an input and a nozzle disposed along the axis of the feedpath when the extruder is placed for use in the three-dimensional printer, the input coupled to the nozzle by a chamber within the extrusion head for passage of the filament, the extrusion head coupled to the extruder such that the extrusion head can move linearly along the axis of the feedpath relative to the extruder;

a spring biasing the extrusion head along the feedpath with a predetermined spring force to movably retain the extrusion head in a position relative to the extruder in an absence of a force applied by the filament;

one or more load bearing surfaces on the extruder to vertically support the extruder against displacement along the axis of the feedpath under the force applied by the filament and retain the extruder in a vertical position along the feedpath during extrusion when the extruder is placed for use in the three-dimensional printer, printer, the extruder further including one or more mechanical features keyed to the three-dimensional printer and configured to controllably retain the extruder against lateral or rotational displacement out of engagement with the three-dimensional printer when placed for use;

a heat sink coupled to the extrusion head; and

circuitry to identify the extrusion head to the three-dimensional printer.

2. The device of claim 1 further comprising one or more mechanical stops to limit an axial travel of the extrusion head along the axis of the feedpath.

3. The device of claim 1 wherein the extruder is magnetically coupled to the three-dimensional printer to resist displacement of the extruder when the extruder is placed for use in the three-dimensional printer.

4. The device of claim 1 wherein the spring includes a coil spring disposed about the axis of the feedpath when the extruder is placed for use in the three-dimensional printer.

5. The device of claim 1 wherein the spring biases the extrusion head away from a load bearing surface of the extruder with a predetermined spring force.

6. The device of claim 1 wherein extruder is coupled in a fixed relationship to a mount of the three-dimensional printer when the extruder is placed for use in the three-dimensional printer.

7. A modular tool for use with a three-dimensional printer, the modular tool comprising:

a mechanical component for modular operation, the mechanical component configured to removably and replaceably couple to the three-dimensional printer in a predetermined alignment to an axis of a feedpath for a filament of build material driven by a drive assembly of the three-dimensional printer and in a fixed relationship to the drive assembly along the feedpath, the mechanical component including one or more load bearing surfaces to vertically support the mechanical component against displacement along the axis of the feedpath under a force applied by the filament along the feedpath, the mechanical component further including one or more mechanical features keyed to the three-dimensional printer and configured to controllably retain the mechanical component against lateral or rotational displacement out of engagement with the three-dimensional printer when placed for use;

an extrusion head including an input and a nozzle disposed along the axis of the feedpath when the mechanical component is placed for use in the three-dimensional printer, the input coupled to the nozzle by a chamber within the extrusion head for passage of the filament, the extrusion head moveably coupled to the mechanical component to permit movement of the extrusion head relative to the mechanical component along the axis of the feedpath;

a spring biasing the extrusion head along the feedpath with a predetermined spring force to movably retain the extrusion head in a position relative to the mechanical component in an absence of the force applied by the filament along the feedpath;

a heat sink coupled to the extrusion head; and

circuitry to identify the extrusion head to the three-dimensional printer.

8. The modular tool of claim 7 wherein the modular tool includes one or more registration features to align the mechanical component to the axis of the feedpath when the mechanical component is placed for use in the three-dimensional printer.

9. The modular tool of claim 7 wherein the mechanical component partially encloses the axis of the feedpath.

10. The modular tool of claim 7 wherein the spring includes a coil spring disposed about the axis of the feedpath.

11. The modular tool of claim 7 further comprising a heating element adjacent to the extrusion head and positioned to liquefy the filament within the chamber of the extrusion head.

12. The modular tool of claim 7 further comprising a filament detector to detect a presence of the filament along the feedpath.

13. The modular tool of claim 7 further comprising one or more mechanical stops to limit an axial travel of the extrusion head within the modular tool.

14. The modular tool of claim 7 wherein the mechanical component is magnetically coupled to the three-dimensional printer to secure the mechanical component when placed for use in the three-dimensional printer.

15. The modular tool of claim 7 wherein the circuitry identifies the extrusion head in a manner that can be detected through a connector by the three- dimensional printer when the modular tool is placed for use in the three-dimensional printer.

16. The modular tool of claim 15 wherein the circuitry is configured to identify the extrusion head by at least one of a diameter, a type, a size, a shape, and a serial number.