System and method to control a three-dimensional (3D) printer

Abstract

A three-dimensional (3D) printer device includes a first extruder configured to deposit a material on a deposition platform, an actuator coupled to at least one of the first extruder or the deposition platform, and a controller coupled to the actuator. The controller is configured to cause the first extruder to deposit a first portion of the material corresponding to a first portion of a physical model. The controller may be configured to cause the first extruder to be cleaned, purged, or both, after the first extruder deposits the first portion of the material. The controller may be configured to cause the first extruder to deposit a second portion of the material after the first extruder is cleaned. The second portion of the material corresponds to a second portion of the physical model.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Patent Application No. 62 / 208,222, filed Aug. 21, 2015 and entitled “Closed-Loop 3D Printing Incorporating Sensor Feedback,” U.S. Provisional Patent Application No. 62 / 340,389, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER,” U.S. Provisional Patent Application No. 62 / 340,421, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER,” U.S. Provisional Patent Application No. 62 / 340,453, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTING DEVICE,” U.S. Provisional Patent Application No. 62 / 340,436, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER,” and U.S. Provisional Patent Application No. 62 / 340,432, filed May 23, 2016 and entitled “3D PRINTER CALIBRATION AND CONTROL;” the contents of each of the aforementione...

AI Technical Summary

Benefits of technology

The patent describes a method and device for 3D printing objects using a 3D printer. The method involves obtaining model data, processing it to generate commands for the printer, and depositing materials to form the physical model. The deposited materials can be cleaned, purged, or both to prepare for the next portion of the model. The device includes a first extruder and an actuator for controlling its movement. The method and device can allow for efficient and precise printing of objects using 3D printing technology.

Problems solved by technology

For example, during extrusion, some materials have a tendency to clog or partially clog a nozzle of the extruder.

To illustrate, a decreased flow area of the nozzle can lead to forming lines that have decreased cross-sectional area, which can reduce print quality.

As another example, some materials may aggregate around the nozzle during extrusion to forms clumps that do not occlude the nozzle but can nevertheless lead to problems.

These clumps of material can break loose during extrusion to cause clumps or other line deformities in the deposited material.

For example, while a first extruder is depositing a matrix material, a second extruder may be idle.

Idle extruders may be particularly subject to clogging since flow of material through the extruder may reduce clogging.

If the idle extruder becomes clogged, it can lead to reduced print quality as a result of clumps in material that is later deposited by the extruder.

A kiss can cause an issue with layer stacking if a portion of the kiss extends above the layer on which it is deposited.

A kiss can also, or in the alternative, cause an issue with line arrangement with the layer being printed if the kiss extends beyond the width of its line into an area associated with another line.

A similar issue arises at the end of the line.

Thus, use of the conventional deposition technique illustrated in FIG. 2B may result in undesirable line characteristics, such as the blob 210, which can lead to problems with adhesion of subsequent layers and deformation of the physical model.

In contrast, inertia and mechanical limitations limit a rate at which the extruder can accelerate.

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