Multiplexed 3D printing

Patent metadata

Field	Value
Publication number	US-12539667-B2
Application number	US-202218709303-A
Country	US
Kind code	B2
Filing date	Nov 14, 2022
Priority date	Nov 12, 2021
Publication date	Feb 3, 2026
Grant date	Feb 3, 2026

Abstract

A multiplexed three-dimensional printing system including a printhead block (100) moveable in three-dimensions, the printhead block including a plurality of extruders (101, 103, 105), wherein each of the plurality of extruders is individually switchable between a deposition state and a retraction state, wherein the deposition state deposits a printing material, and wherein the retraction state prevents deposition of the printing material.

First claim

What is claimed is:

1 . A multiplexed three-dimensional printing system comprising:
a printhead block moveable in three dimensions, the printhead block comprising a plurality of extruders, wherein each of the plurality of extruders is individually switchable between a deposition state and a retraction state, wherein the deposition state deposits a printing material, and wherein the retraction state retracts a filament of the printing material to prevent deposition of the printing material; and a controller configured to determine a smallest fit rectangle that bounds a two-dimensional slice of the object, to determine the toolpath within the smallest fit rectangle, and to determine a plurality of points within the smallest fit rectangle for the plurality of extruders at which switches between the deposition state and the retraction state should occur to print the object.

2 . The system according to claim 1 , wherein at least one extruder of the plurality of extruders comprises a filament gear, and
wherein the filament gear is operable in a forward direction to feed the filament of the printing material out of the at least one extruder and in a reverse direction to retract the filament within the at least one extruder.

3 . The system according to claim 1 , further comprising a gantry operatively associated with the printhead block and configured to selectively move the printhead block along at least one of an X-axis, a Y-axis, and a Z-axis.

4 . The system according to claim 1 , further comprising a plurality of rollers, wherein each of the plurality of rollers is associated with one of the plurality of extruders and positioned to apply pressure to the printing material deposited therefrom.

5 . The system according to claim 4 , wherein a nozzle of a respective extruder of the plurality of extruders is disposed between a first roller of the plurality of rollers and a second roller of the plurality of rollers, and wherein the nozzle, the first roller, and the second roller are colinear.

6 . The system according to claim 4 , wherein at least one of the plurality of rollers is heated.

7 . The system according to claim 4 , wherein at least one of the plurality of rollers comprises a spring-biased roller ball.

8 . A method for multiplexed three-dimensional printing an object via a printhead block moveable in three dimensions, the printhead block comprising a plurality of extruders, wherein each of the plurality of extruders is individually switchable between a deposition state and a retraction state, wherein the deposition state deposits a printing material, and wherein the retraction state retracts a filament of the printing material to prevent deposition of the printing material, the method comprising:
moving the printhead block along a toolpath; individually switching the plurality of extruders between the deposition state and the retraction state; and determining a smallest fit rectangle that bounds a two-dimensional slice of the object, determining the toolpath within the smallest fit rectangle, and determining a plurality of points within the smallest fit rectangle for the plurality of extruders at which switches between the deposition state and the retraction state should occur to print the object.

9 . The method according to claim 8 , further comprising:
depositing the printing material to form a deposition of the printing material, and compressing the deposition.

10 . The method according to claim 8 , further comprising retracting the filament of the printing material during the retraction state.

11 . The method according to claim 8 , further comprising selectively moving the printhead block within a gantry that is operatively associated with the printhead block and configured to move the printhead block along at least one of an X-axis, a Y-axis, and a Z-axis.

12 . The method according to claim 8 , further comprising calibrating each of the plurality of extruders based on imaging data of printing material deposited by each of the plurality of extruders.

13 . The method according to claim 12 , wherein the calibration comprises an adjustment of a deposition rate of the printing material.

14 . A system, comprising:
a multiplexed three-dimensional printing system comprising a printhead block moveable in three dimensions, the printhead block comprising a plurality of extruders, wherein each of the plurality of extruders is individually switchable between a deposition state and a retraction state, wherein the deposition state deposits a printing material, and wherein the retraction state retracts a filament of the printing material to prevent deposition of the printing material; and a controller configured to control movement of the printhead block and to control individually switching the plurality of extruders between the deposition state and the retraction state, wherein the controller is further configured to determine a smallest fit rectangle that bounds a two-dimensional slice of the object, to determine the toolpath within the smallest fit rectangle, and to determine a plurality of points within the smallest fit rectangle for the plurality of extruders at which switches between the deposition state and the retraction state should occur to print the object.

15 . The system according to claim 14 , wherein at least one extruder of the plurality of extruders comprises a filament gear configured to selectively feed or retract the filament of the printing material, and
wherein the controller is further configured to selectively control the filament gear to feed or retract the filament.

16 . The system according to claim 14 , wherein the multiplexed three-dimensional printing system further comprises a gantry operatively associated with the printhead block and configured to selectively move the printhead block along at least one of an X-axis, a Y-axis, and a Z-axis,
wherein the controller is further configured to control the gantry to selectively move the printhead block.

17 . The system according to claim 14 , wherein the system further comprises a camera system communicatively coupled to the controller and positioned relative to the printhead block to acquire images of printing material deposited by the plurality of extruders,
wherein the controller is configured to control the camera to selectively acquire the images of the printing material deposited by the plurality of extruders.

18 . The system according to claim 17 , wherein the controller is further configured to develop a toolpath for the printhead block based at least in part on the images.

19 . The system according to claim 14 , wherein the controller is further configured to allow for one or more of the plurality of extruders to compensate for one of the plurality of extruders that is in a malfunctioning state by depositing the printing material that would otherwise be deposited by the one of the plurality of extruders that is in the malfunctioning state.

Assignees

• Univ Rutgers

Inventors

• Malhotra Rajiv
• Cleeman Jeremy

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · 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

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title