Methods and apparatus for processing and dispensing material during additive manufacturing

Patent metadata

Field	Value
Publication number	US-12496777-B2
Application number	US-202418795789-A
Country	US
Kind code	B2
Filing date	Aug 6, 2024
Priority date	Aug 31, 2016
Publication date	Dec 16, 2025
Grant date	Dec 16, 2025

Abstract

An additive manufacturing machine includes a first segment that is movable while the additive manufacturing machine deposits material, a second segment being configured to move relative to the first segment, and an extruder having a screw disposed within a barrel. The machine also includes a pump having an inlet and an outlet, a nozzle physically coupled to the second segment and configurable to: (i) translate along a first axis, along a second axis perpendicular to the first axis, and along a third axis and (ii) dispense the material, and a controller configured to control a speed of the screw of the extruder and a speed of the pump based on increases or decreases in movement of the nozzle along at least two axes of the first axis, the second axis, and the third axis, in operation during deposition of the material in an arc or corner.

First claim

We claim:

1 . An additive manufacturing machine, comprising:
a first segment that is movable while the additive manufacturing machine deposits material; a second segment connected to the first segment, the second segment configured to move with the first segment while the additive manufacturing machine deposits material, the second segment being further configured to move relative to the first segment; an extruder having a screw disposed within a barrel; a pump having an inlet and an outlet, wherein the inlet is in fluid communication with the extruder; a pressure sensor configured to sense a pressure for the inlet of the pump; a nozzle physically coupled to the second segment and configurable to: (i) translate along a first axis, along a second axis perpendicular to the first axis, and along a third axis orthogonal to the first axis and to the second axis and (ii) dispense the material; and a controller configured to receive the sensed pressure from the pressure sensor and to control a speed of the screw of the extruder and a speed of the pump based on increases or decreases in movement of the nozzle along at least two axes of the first axis, the second axis, and the third axis, in operation during deposition of the material in an arc or corner.

2 . The machine of claim 1 , wherein the pump is a gear pump.

3 . The machine of claim 1 , wherein the controller is further configured to control a speed of at least one of the extruder and the pump based on a rate of translation of the nozzle and pressure sensed with the pressure sensor.

4 . The machine of claim 1 , wherein the controller is further configured to control a speed of at least one of the extruder and the pump based on at least one of a rate of translation of the nozzle and the pressure sensed with the pressure sensor.

5 . The machine of claim 1 , wherein the second segment is configured to pivot relative to first segment.

6 . The machine of claim 1 , further including a worktable having a displaceable support surface.

7 . The machine of claim 1 , further including a servomotor configured to drive the pump via a gearbox.

8 . The machine of claim 1 , further including a gantry that is coupled to the first segment and to the second segment via a carrier.

9 . An additive manufacturing machine, comprising:
a first segment; a second segment connected to the first segment, the second segment being movable with the first segment and configurable to pivot to position the second segment; an extruder having a screw disposed within a barrel; a nozzle connected to the second segment and configurable to translate along a first axis, along a second axis perpendicular to the first axis, and along a third axis orthogonal to the first and second axes, the nozzle being configurable to pivot together with the second segment; and a track along which the first segment, the second segment, the extruder, and the nozzle are displaceable during operation of the additive manufacturing machine.

10 . The machine of claim 9 , further including a gear pump in fluid communication with the extruder.

11 . The machine of claim 10 , further including a controller configurable to control a speed of at least one of the extruder and the pump based on at least one of a rate of translation of the nozzle and pressure sensed with a pressure sensor.

12 . The machine of claim 10 , further including a controller configurable to adjust a speed of the extruder and a speed of the pump.

13 . The machine of claim 10 , further including a controller configurable to adjust a speed of the extruder and a speed of the pump relative to each other.

14 . The machine of claim 9 , further including a gantry that is moveable along the first axis.

15 . An additive manufacturing machine, comprising:
a first segment that is movable while the additive manufacturing machine deposits material; a second segment configured to move with the first segment while the additive manufacturing machine deposits material, the second segment being further configured to move relative to the first segment; an extruder having a screw disposed within a barrel; a pressure sensor configured to sense a pressure downstream of the extruder; a nozzle physically coupled to the second segment and configurable to: (i) translate along a first axis, along a second axis perpendicular to the first axis, and along a third axis orthogonal to the first and second axes, the nozzle being translatable along a track that is aligned with the first axis, the second axis, or the third axis, and (ii) dispense the material; and a controller configurable to receive the sensed pressure from the pressure sensor and to control a speed of the screw of the extruder.

16 . The machine of claim 15 , further including a positive displacement gear pump in fluid communication with the extruder.

17 . The machine of claim 15 , wherein the controller is configurable to adjust a speed of the extruder and a speed of a pump.

18 . The machine of claim 15 , further including an applicator that carries the nozzle, the applicator being connected to the second segment, the first segment and the second segment being supported with a gantry.

19 . The machine of claim 15 , further including:
an applicator that carries the nozzle, the applicator being connected to the second segment, the first segment and the second segment being supported with a gantry; and a carrier supporting the extruder and a pump with the gantry.

20 . The machine of claim 15 , further including tracks and a gantry that is displaceable along the tracks to move the nozzle.

Assignees

• Thermwood Corp

Inventors

• Susnjara Kenneth J
• Vote Nicolas
• Gaesser Robert
• Smiddy Brian S
• Vaal Scott G

Classifications

• B29C64/118

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

• B29C64/379

  Handling of additively manufactured objects, e.g. using robots · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title

• B33Y30/00

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

• B33Y10/00

  Processes of additive manufacturing · CPC title