Methods for composite filament threading in three dimensional printing

Patent metadata

Field	Value
Publication number	US-11065861-B2
Application number	US-201514942656-A
Country	US
Kind code	B2
Filing date	Nov 16, 2015
Priority date	Mar 22, 2013
Publication date	Jul 20, 2021
Grant date	Jul 20, 2021

Abstract

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to applying the filament from the conduit nozzle.

First claim

What is claimed is:

1. A three dimensional printer capable of printing a part, comprising:
a print head housing a conduit nozzle having a nozzle outlet, the print head configured to receive a reinforced filament having a matrix material impregnating reinforcing strands aligned along the reinforced filament, the conduit nozzle configured to allow the reinforced filament to be both pushed and pulled through the conduit nozzle, and the nozzle outlet configured to fuse the reinforced filament to the part;
a filament feed path extending through a cold feed zone within the print head that is configured to be cooler than the nozzle outlet and is configured to keep the reinforced filament sufficiently stiff to be pushed through the filament feed path until an unattached terminal end approaches the nozzle outlet;
a filament feed drive and a part drive for relatively moving the nozzle outlet and the part, the filament feed drive and the part drive configured to translate the reinforced filament to follow the filament feed path and to force the unattached terminal end to abut the part while relatively moving the nozzle outlet and the part, the filament feed drive comprising a slipping mechanism constructed and arranged to permit the reinforced filament to be pulled through the conduit nozzle;
a nozzle outlet heater configured to heat the nozzle outlet;
a cutter configured to cut the reinforced filament in a location along the filament feed path to the nozzle outlet; and
a controller configured to control the filament feed drive and the part drive to move the nozzle outlet and the part to deposit a remaining cut segment portion of the reinforced filament to the part,
wherein the cold feed zone abuts the nozzle outlet and is constructed of a material less thermally conductive than a material of which the nozzle outlet is constructed.

2. The three dimensional printer according to claim 1 , wherein the controller is configured to control the filament feed drive and the part drive to feed forward the unattached terminal end of the reinforced filament into the cold feed zone, the cold feed zone configured to be at a temperature at which the matrix material is unmelted.

3. The three dimensional printer according to claim 2 , wherein the cold feed zone comprises a receiving tube arranged to receive the unattached terminal end and support the reinforced filament.

4. The three dimensional printer according to claim 3 , wherein a guide tube guiding the reinforced filament is positioned along a threaded path upstream of the receiving tube, and a bore of the receiving tube is larger than a bore of the guide tube.

5. The three dimensional printer according to claim 1 , wherein the controller is configured to control the filament feed drive and the part drive to push forward the unattached terminal end through a heated cavity of the conduit nozzle and through a rounded tip terminating the heated cavity.

6. The three dimensional printer according to claim 5 , wherein a bore of the heated cavity is larger than at least one receiving tube upstream along a threaded path from the heated cavity.

7. The three dimensional printer according to claim 1 , wherein the controller is configured to control the filament feed drive and the part drive to maintain the reinforced filament in a substantially unmelted state until the reinforced filament contacts a wall of the nozzle outlet.

8. The three dimensional printer according to claim 1 , wherein the controller is configured to control the filament feed drive and the part drive to contact the nozzle outlet with the reinforced filament as the reinforced filament is translated out of the nozzle outlet.

9. The three dimensional printer according to claim 1 , wherein the controller is configured to control the filament feed drive, the part drive and the nozzle outlet heater to melt the matrix material of the terminal end to fuse to the part at a rounded tip of the conduit nozzle.

10. The three dimensional printer according to claim 1 , wherein the controller is configured to control the filament feed drive, the part drive and the cutter to cut the reinforced filament at a temperature at which the matrix material is unmelted, and rethread the unattached terminal end through the conduit nozzle.

11. The three dimensional printer according to claim 10 , wherein the controller is configured to control the filament feed drive and the part drive to drag forward the reinforced filament through the conduit nozzle by applying a force at least via the reinforcing strands.

12. The three dimensional printer according to claim 10 , wherein the controller is configured to control the filament feed drive and the part drive to apply pressure with the conduit nozzle to continuously compact the reinforced filament before the reinforced filament has fused into the part.

13. The three dimensional printer according to claim 1 , the conduit nozzle comprising a lip forming a smooth transition between a vertical feeding path and a horizontal printing path, and wherein the controller is configured to control the filament feed drive and the part drive to apply pressure with the lip to continuously compact the reinforced filament as the reinforced filament is fused into the part.

14. The three dimensional printer according to claim 13 , wherein the controller is configured to control the filament feed drive and the part drive to drag forward the reinforced filament through the conduit nozzle by applying a force at least via the reinforcing strands.

15. The three dimensional printer according to claim 13 , wherein the controller is configured to control the filament feed drive, the part drive and the cutter to cut the reinforced filament at a temperature in which the matrix material is unmelted.

16. A three dimensional printer capable of printing a part, comprising:
a print head housing a conduit nozzle having a nozzle outlet, the print head configured to receive a reinforced filament having a matrix material impregnating reinforcing strands aligned along the reinforced filament, the conduit nozzle configured to allow the reinforced filament to be both pushed and pulled through the conduit nozzle, and the nozzle outlet configured to fuse the reinforced filament to the part;
a first guide tube;
a second guide tube;
a receiving tube;
a filament feed drive and a part drive for relatively moving the nozzle outlet and the part, the filament feed drive and the part drive configured to translate the reinforced filament to follow the second guide tube and to force the unattached terminal end to abut the part while relatively moving the nozzle outlet and the part, the filament feed drive comprising a slipping mechanism constructed and arranged to permit the reinforced filament to be pulled through the conduit nozzle;
a nozzle outlet heater configured to heat the nozzle outlet;
a cutter configured to cut the reinforced filament in a location along a filament feed path to the nozzle outlet; and
a controller configured to control the filament feed drive and part drive to move the nozzle outlet and the part to deposit a remaining cut segment portion of the reinforced filament to the part,
wherein the second guide tube is located downstream of the filament feed drive and is configured to prevent buckling of the reinforced filament until an unattached terminal end approaches the nozzle outlet, the first guide tube is located upstream of the filament feed drive and is configured to facilitate guiding and maintaining alignment of the reinforced filament with the filament feed drive, and the receiving tube is located downstream of the

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas
• Gozdz Antoni S

Classifications

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/118 Primary

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B33Y30/00 Primary

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• G06F2113/10

  Additive manufacturing, e.g. three-dimensional [3D] printing · CPC title