Ribbon filament and assembly for use in extrusion-based digital manufacturing systems

Patent metadata

Field	Value
Publication number	US-2017136691-A1
Application number	US-201715420771-A
Country	US
Kind code	A1
Filing date	Jan 31, 2017
Priority date	Sep 30, 2009
Publication date	May 18, 2017
Grant date	—

Abstract

A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.

First claim

1 - 20 . (canceled)

21 . A non-cylindrical ribbon filament for use in an extrusion-based digital manufacturing system with a ribbon liquefier to build a three-dimensional model in a layer-by-layer manner, the ribbon filament comprising:
a composition comprising at least one extrudable material; a length that is continuous for at least a distance such that the non-cylindrical ribbon filament is feedable from a supply source to the ribbon liquefier configured to melt and extrude the filament, the ribbon liquefier retained by a moveable head of the extrusion-based digital manufacturing system; a cross-sectional profile of the length having a cross-sectional aspect ratio of 2:1 or greater; and wherein the non-cylindrical ribbon filament exhibits a flexibility such that the ribbon filament does not plastically deform or fracture while retained by the supply source or when fed from the supply source to the ribbon liquefier.

22 . The non-cylindrical ribbon filament of claim 21 , wherein the at least one extrudable material comprises a thermoplastic polymeric material.

23 . The non-cylindrical ribbon filament of claim 21 , wherein the cross-sectional profile is configured to mate with the non-cylindrical ribbon liquefier having an entrance cross-sectional area A e and a hydraulic diameter D h with the ribbon filament, wherein D h <0.95√{square root over (A e )}.

24 . The non-cylindrical ribbon filament of claim 23 , wherein D h <0.90 √{square root over (A e )} and D h >0.40 √{square root over (A e )}.

25 . The non-cylindrical ribbon filament of claim 21 , wherein the aspect ratio ranges from about 2.5:1 to about 20:1.

26 . The non-cylindrical ribbon filament of claim 21 , wherein the aspect ratio ranges from about 3:1 to about 10:1.

27 . The non-cylindrical ribbon filament of claim 21 , wherein the aspect ratio ranges from about 3:1 to about 8:1.

28 . An assembly for use in an extrusion-based digital manufacturing system with a ribbon liquefier to build a three-dimensional model in a layer-by-layer manner, the assembly comprising:
a supply source configured to engage the extrusion-based digital manufacturing system; and a non-cylindrical ribbon filament retained by the supply source, the ribbon filament comprising: a composition comprising at least one extrudable material; a length that is continuous for at least a distance such that the ribbon filament is feedable from the supply source to the ribbon liquefier retained by a moveable head of the extrusion-based digital manufacturing system; and a cross-sectional profile of the length, which is configured to mate with the ribbon liquefier having an entrance cross-sectional area A e and a hydraulic diameter D h with the ribbon filament, wherein D h <0.95 √{square root over (A e )}, and wherein the non-cylindrical ribbon filament along the length has a cross-sectional aspect ratio greater than 2:1; wherein the non-cylindrical ribbon filament exhibits a flexibility such that the ribbon filament does not plastically deform or fracture while retained by the supply source; and wherein the non-cylindrical ribbon filament further exhibits a Young's Modulus value ranging from about 1.0 gigapascal to about 5.0 gigapascals.

29 . The assembly of claim 28 , wherein the at least one extrudable material comprises a thermoplastic polymeric material.

30 . The assembly of claim 28 , wherein D h <0.90 √{square root over (A e )}, and D h >0.40 √{square root over (A e )}.

31 . The assembly of claim 28 , wherein the aspect ratio ranges from about 2.5:1 to about 20:1.

32 . The assembly of claim 28 , wherein the aspect ratio ranges from about 3:1 to about 10:1.

33 . The assembly of claim 28 , wherein the aspect ratio ranges from about 3:1 to about 8:1.

34 . An assembly for use in an extrusion-based digital manufacturing system with a ribbon liquefier to build a three-dimensional model in a layer-by-layer manner, the assembly comprising:
a container configured to engage the extrusion-based digital manufacturing system; a pathway from the container and configured to extend to a ribbon liquefier retainable by a moveable head of the extrusion-based digital manufacturing system; and a non-cylindrical ribbon filament at least partially retained within the container and feedable through the pathway from the container to the ribbon liquefier, the non-cylindrical ribbon filament comprising:
a composition comprising at least one extrudable material;
a length;
a cross-sectional profile of the length, which is configured to mate with the ribbon liquefier having an entrance cross-sectional area A e and a hydraulic diameter D h with the ribbon filament, wherein D h <0.95 √{square root over (A e )}, and wherein the non-cylindrical ribbon filament along the length has a cross-sectional aspect ratio greater than 2:1.

35 . The assembly of claim 34 , wherein the at least one extrudable material comprises a thermoplastic polymeric material.

36 . The assembly of claim 34 , wherein D h <0.90 √{square root over (A e )} and D h >0.40√{square root over (A e )}.

37 . The assembly of claim 34 , wherein the aspect ratio ranges from about 2.5:1 to about 20:1.

38 . The assembly of claim 34 , wherein the aspect ratio ranges from about 3:1 to about 10:1.

39 . The assembly of claim 34 , wherein the aspect ratio ranges from about 3:1 to about 8:1.

40 . The assembly of claim 34 , wherein D h <0.90 √{square root over (A e )} and D h >0.40 √{square root over (A e )}.

Assignees

• Stratasys Inc

Inventors

• Batchelder J Samuel
• Swanson William J
• Crump S Scott

Classifications

• B29C64/118

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

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B32B38/185

  combined with the cutting of one or more layers · CPC title

• B32B38/0004

  Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence) · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title