Multi-axis movement for multi-component reactive extrusion printing

Abstract

An additive manufacturing system including a multi-axis additive manufacturing device and a rotating / tilting printing bed for multi-axis movement for multi-component reactive extrusion printing, and methods of using the same, is disclosed.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 507,879, filed June 13, 2023, entitled “MULTIAXIS MOVEMENT FOR MULTICOMPONENT REACTIVE EXTRUSION PRINTING,” pursuant to 35 USC § 119(e), which is incorporated herein by reference in its entirety.

[0003] Government licensing rights

[0004] This invention was made with government support under Government Contract No. W911NF-17-2-0227 Additive Manufacturing (U.S. Army Research Laboratory, ARL). The government may own certain rights to this invention. Technical Field

[0005] This disclosure relates to a multi-axis additive manufacturing system, which includes a multi-axis additive manufacturing apparatus and a rotary / tilting print bed for multi-axis movement for multi-component reactive extrusion printing. Background Technology

[0006] 3D printing is a process used to create objects from cured compositions such as plastics. The cured composition can be made from thermosetting compositions. During the printing of an object using a thermosetting composition, at least two co-reactive components are mixed together to produce a co-reactive composition or printable composition. Thermosetting compositions can be used in environmental reactive extrusion (ARE) printing, where the co-reactive composition is deposited onto a print bed through a printhead using an additive manufacturing apparatus and cured under environmental conditions.

[0007] When printing using an additive manufacturing apparatus that moves along up to three axes and a stationary print bed, support structures may be needed to support parts of the 3D printed object that may sag, drip, or otherwise move due to gravity. Moving the additive manufacturing apparatus only on two axes may limit the shapes and angles produced and increase printing time due to the need for printing support structures. Summary of the Invention

[0008] This disclosure provides a method for printing 3D articles, the method comprising: combining a first co-reacting component and a second co-reacting component in a mixing assembly of a printhead coupled to a multi-axis movable manipulator, the first co-reacting component and the second co-reacting component reacting to form a first printable composition; moving the printhead while extruding the first printable composition to print a first portion of a 3D printed article onto a print bed, wherein the print bed is disposed in a first orientation; moving the print bed to a second orientation not parallel to the first orientation; and moving the printhead while extruding the first printable composition to print a second portion of the 3D printed article onto the first portion of the 3D printed article. The first portion of the 3D printed article is printed along a first axis, and the second portion of the 3D printed article is printed along a second axis, which is not parallel to the first axis.

[0009] This disclosure further provides an additive manufacturing system for printing 3D objects, the additive manufacturing system including a multi-axis movable manipulator and a tiltable and rotatable print bed. The multi-axis movable manipulator includes: a base fixed to a surface; a first arm rotatably coupled to the base; a second arm rotatably coupled to the first arm at its proximal end; and a print head rotatably coupled to the distal end of the second arm. The first and second arms are each configured to rotate about different axes of rotation, such that the multi-axis movable manipulator can move along at least four axes of rotation. The tiltable and rotatable print bed includes: a base fixed to an anchoring surface; and a printing surface coupled to the base. The printing surface is configured to tilt between a horizontal and a non-horizontal position and also rotate about an axis. Attached Figure Description

[0010] The above and other features and advantages of this disclosure, as well as the ways in which they are obtained, will become more apparent from the following description taken in conjunction with the accompanying drawings, and the disclosure itself will be better understood. The above and other features of this disclosure can be used in any combination or arrangement.

[0011] Figure 1 It is a front view of an additive manufacturing system including a multi-axis additive manufacturing apparatus for multi-axis moving 3D printing and a rotary printing bed;

[0012] Figure 2 It is connected to Figure 1 A perspective view of the printhead at the far end of a multi-axis additive manufacturing apparatus;

[0013] Figure 3 Is Figure 1 A perspective view of a multi-component printhead at the end of a multi-axis additive manufacturing apparatus;

[0014] Figure 4 It is along Figure 3A cross-sectional view of axis A of a multi-component printhead;

[0015] Figure 5 yes Figure 3 Front perspective view of the mixing components within the diamond mount of a multi-component printhead;

[0016] Figure 6 It shows the use Figure 3 A flowchart of a method for printing 3D objects using a multi-component printhead;

[0017] Figure 7 It shows the use Figure 3 A flowchart of a method for printing 3D objects using a multi-component printhead;

[0018] Figure 8A This is an illustration of an additive manufacturing apparatus and a stationary printing bed printing a 3D object with a supporting structure; and

[0019] Figure 8B yes Figure 1 An illustration of an additive manufacturing device and a rotary printing bed that prints 3D objects without a support structure.

[0020] Figure 9A This is an illustration of a 3D printed object, where part of the structure includes a cantilever.

[0021] Figure 9B Is it printing? Figure 9A An illustration of the bottom part of a 3D object;

[0022] Figure 9C is Further printing Figure 9B An illustration of the bottom part of a 3D object;

[0023] Figure 9D It involves rotating the print bed to print without any supporting structure. Figure 9A An illustration of the top portion of a 3D object;

[0024] Figure 9E It involves rotating the print bed for further printing without a support structure. Figure 9D An illustration of the top portion of a 3D object;

[0025] Figure 10A This is a diagram illustrating the printing limitations of an additive manufacturing apparatus with a limited range of motion.

[0026] Figure 10B yes Figure 1 How can additive manufacturing systems print 3D objects without printing limitations?

[0027] Figure 11A By using a rotary multi-axis additive manufacturing device and fixing Figure 1 An illustration of the first method for printing 3D objects using a printing bed;

[0028] Figure 11B By rotating Figure 1 An illustration of a second method for printing 3D objects using a printing bed;

[0029] Figure 12A This is an illustration of fixed printing using an additive manufacturing device;

[0030] Figure 12B Is using Figure 1 An illustration of an additive manufacturing apparatus performing conformal printing;

[0031] Figure 13 yes Figure 1 A perspective side view of a rotating and tilted printing bed; and

[0032] Figure 14 This is a schematic diagram of a computer system used for additive manufacturing.

[0033] In the various views, corresponding reference numerals denote corresponding parts. The examples illustrated herein illustrate this disclosure, and such examples should not be construed as limiting the scope of this disclosure in any way. Detailed Implementation

[0034] This disclosure provides a multi-axis additive manufacturing system, which includes a multi-axis additive manufacturing apparatus and a rotatable and tiltable print bed.

[0035] I. Definition

[0036] For the purposes of the following detailed description, it should be understood that this disclosure may take various alternative variations and sequences of steps unless the contrary is explicitly stated. Furthermore, except in any operational instance, or where otherwise indicated, all figures used in the specification and claims to indicate, for example, the quantity of components, should be understood to be modified by the term "about" in all cases. For example, numerical ranges provided for the weight percentage of a component or the amount of added component should be interpreted as being modified by the term "about." Therefore, unless otherwise indicated, the numerical parameters set forth in the following specification and appended claims are approximations that can be varied according to the desired properties obtained through this disclosure. At least, and not in an attempt to limit the application of the equivalence principle to the scope of the claims, each numerical parameter should be interpreted at least according to the number of significant figures reported and by applying common rounding techniques.

[0037] Although the numerical ranges and parameters described in this disclosure are approximate, the values ​​presented in specific examples are reported as precisely as possible. However, any numerical value inherently contains some error that is necessarily caused by the standard deviation found in its corresponding test measurement results.

[0038] Furthermore, it should be understood that any numerical range described herein is intended to include all subranges included therein. For example, the range “1 to 10” is intended to include all subranges from the described minimum value of 1 to the described maximum value of 10 (and include both the minimum and maximum values), that is, a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.

[0039] The use of the singular includes the plural, and the plural encompasses the singular, unless otherwise explicitly stated. Furthermore, unless otherwise specifically stated, the use of "or" means "and / or," even if "and / or" may be explicitly used in certain instances.

[0040] "Printing" refers to any process in which one material is deposited onto and / or reacts with another material and / or itself, such as 3D printing.

[0041] "Co-reactive composition" refers to a composition comprising at least two different compounds that are capable of chemically reacting with each other to form a covalent bond.

[0042] "Co-reactive component" refers to a compound containing at least one reactive functional group, which reacts when combined with a chemically compatible functional group to form a co-reactive composition.

[0043] A "reactive functional group" is a chemical group that can react chemically with another reactive functional group to form a covalent bond.

[0044] A "reactive compound" is a compound that includes at least one reactive functional group.

[0045] "Extrusion" refers to a process used to create objects, in which material is pushed through a die. Extrusion dies have a shape and size suitable for constructing objects. Extrusion dies can have a fixed shape or a shape that can be changed during extrusion.

[0046] "Filler" means any compound added to a reactive compound or co-reactive composition that does not react with at least a portion of the compound and / or composition. As used herein, filler encompasses particles, fibers, slurries, mixtures, and any other compounds and combinations thereof that may be added to reactive compounds and / or co-reactive compositions.

[0047] "ARE" or environmental reactive extrusion refers to any additive manufacturing process that incorporates a printable composition containing co-reactive components.

[0048] “Environmental conditions” refers to room temperature (e.g., about 20°C to 28°C, such as 23°C), relative humidity at or near 45%, and atmospheric pressure (e.g., 1 atm).

[0049] II. Co-reaction chemical properties

[0050] Additive manufacturing using co-reactive compositions, also known as environmental reactive extrusion or ARE-type 3D printing, typically utilizes at least two components that react with each other (e.g., co-react). A first co-reactive component (sometimes referred to herein as a first reactant group, first reactive functional group, or part A) and at least one second co-reactive component (sometimes referred herein as a second reactant group, second reactive functional group, or part B) chemically react with each other during extrusion in a combined and / or continuous manner to form a co-reactive composition. The co-reactive composition may then be cured under environmental conditions or, depending on the chemical nature of the reaction, with the assistance of, for example, heating, photochemical radiation, a catalyst, or the addition of a post-extrusion curing agent, to form an object or part of an object comprising a thermosetting polymer (sometimes referred to as a thermosetting plastic), a thermoplastic polymer, or a combination thereof. Those skilled in the art select at least the first and second co-reactive components to obtain the desired end product (e.g., a thermosetting plastic, a thermoplastic plastic, etc.).

[0051] Three-dimensional objects formed from co-reactive compositions are additively manufactured by extruding the co-reactive composition, which is in at least a partially reacted state, onto a surface such as a building platform. The co-reactive composition may be in at least a partially reacted state during extrusion, and then fully reacted and cured to form a layer of co-reactive composition. Continuous layers of the same or different co-reactive compositions may be deposited to form additional material layers. The co-reactive composition may react at least partially when the co-reactive components do not aggregate together before extrusion (e.g., in a mixing volume). Alternatively, the two co-reactive components may be premixed before extrusion and treated in a way that inhibits reaction (e.g., inhibits curing of the co-reactive composition), such as freezing the composition during mixing.

[0052] It may be desirable to select the chemical properties of each layer of the deposited co-reactive composition to form covalent bonds between successive material layers. Furthermore, different parts of the article can be printed from different co-reactive compositions (e.g., printing a first co-reactive composition to form a first part of the object, such as a base portion, internal structure, etc., and printing a second co-reactive composition to form a second part of the object), and covalent bonds can also be formed between different materials depending on the chemical reactivity between the different co-reactive compositions.

[0053] Specifically, printable articles can have rigid and flexible portions, rigid and foamy portions, tactile portions and rigid and / or flexible portions, two portions with different densities, one or more conductive portions, one or more thermally / electrically conductive portions, two or more different colors, two or more different rheological property profiles, two or more different materials with different affinities to water and / or solvents, etc. Articles can also be printed such that a co-reactive composition is deposited onto an existing article (e.g., other thermosetting and / or thermoplastic plastics, metals, wood, composites, ceramics, etc.) to produce an article comprising both the co-reactive composition and a non-co-reactive composition.

[0054] Due to the covalent bonding between printed layers, additive manufacturing, as described herein, yields objects with significantly higher strength, particularly along the Z-axis (e.g., vertical), compared to other extruded or printed parts. Strong intralayer and interlayer covalent bonding not only produces more robust parts but also more uniform part geometry; i.e., fewer print lines and / or partial variations. The ability to form objects with multiple substrates and / or portions comprising different co-reactive or non-co-reactive compositions in a single process is another advantage.

[0055] Table 1 describes suitable co-reactive compositions and the co-reactive components that can form them. These co-reactive compositions can be printed (alone or in combination) using any of the methods described herein to form three-dimensional objects.

[0056]

[0057] Another advantage of additive manufacturing using co-reactive compositions is that these compositions can be 3D printed at relatively low viscosities. Therefore, relatively large amounts (e.g., high relative weight percentages) of additives and / or fillers can be included in the co-reactive components while maintaining printable viscosity. Both the type and / or amount of additives can be selected or “tuned” to obtain the desired chemical and / or physical properties of the printed article. Co-reactive compositions can be tuned by adding additives and / or fillers to obtain desired mechanical properties (e.g., strength, elasticity, stiffness, anti-sagging, etc.), surface properties (e.g., hardness, texture, smoothness, etc.), chemical resistance (e.g., solvent resistance, etc.), heat resistance (including flame retardancy, etc.), or thermal conductivity, and / or electrical insulation or conductivity. Co-reactive compositions can also be tuned by adding one or more catalytic / activator / promoter additives to any co-reactive component to obtain desired reaction kinetics, such as reaction rate.

[0058] Table 2 describes additives that can be included in any co-reaction composition, such as those described in Table 1. Depending on the desired chemical and / or physical properties of the resulting object, additives may be included in either or both of the first and second co-reaction components (e.g., either or both of Part A and Part B). In this case, Table 2 describes specific additives and fillers suitable for 3D printing based on environmentally reactive extrusion, but Table 2 is not limiting. Therefore, other additives, such as those known to those skilled in the art of coatings, extrusion, and thermoplastics, may be included in the co-reaction composition.

[0059]

[0060] Any suitable co-reactive composition and optional additives / fillers can be printed using a 3D printing system suitable for mixing and extruding raw materials. Two or more volumetric metering pumps (e.g., positive displacement pumps, screw pumps, etc.) can each discharge the two co-reactive components associated with the co-reactive composition in a combined or continuous manner (e.g., a first reactive component pumped into a mixing volume by a first metering pump and a second co-reactive component pumped into a second metering pump). In some cases, the mixing volume may incorporate mechanical (e.g., driven) mixing properties. Upon entering the mixing volume, the first and second co-reactive components begin to mix and react, and are then extruded through the extrusion printing nozzle in a state of at least partial reaction. Once extruded, the two co-reactive components further react and solidify, as described above, which can occur under ambient conditions to form a thermosetting material, a thermoplastic material, or a combination thereof.

[0061] III. Multi-axis additive manufacturing apparatus

[0062] This disclosure provides an additive manufacturing system 100 for 3D printing objects using co-reactive compositions, such as... Figure 1 As seen in the image. System 100 includes a printing bed 110 and an additive manufacturing apparatus 120 with multiple axes.

[0063] A. Printing bed

[0064] like Figure 1 and Figure 13As seen, the print bed 110 may include a print surface 112 and a base 114. The base 114 may be fixed to an anchoring surface 101, such as the ground, ceiling, wall, or any other anchoring surface, at a predetermined distance D1 from the additive manufacturing apparatus 120. The base 114 may include a base plate 115, which includes at least one fastener 116 to secure the print bed 110 to the anchoring surface 101. The print surface 112 may be coupled to the base 114 such that a first face 113 of the print surface 112 faces upward and away from the base 114 and the base plate 115. The first face 113 may be configured to receive a 3D printed object formed by additive manufacturing using a print head 130 coupled to the additive manufacturing apparatus 120, as discussed below.

[0065] The printing surface 112 is rotatable along a first axis 111a and a second axis 111b. The first axis 111a can be a rotation that allows the printing surface 112 to rotate 360 ​​degrees about axis Y. The second axis 111b can allow the printing surface 112 to tilt toward and away from the additive manufacturing apparatus 120 on axis X.

[0066] B. Multi-axis device 120

[0067] The additive manufacturing apparatus 120 may be a multi-axis device or a multi-axis movable manipulator. Alternatively, the apparatus 120 may be a multi-axis robot or other mechanically driven device including a controller that programs the apparatus to perform tasks. The apparatus 120 may include a base 122, at least one arm 124 rotatably coupled to the base 122, and a printhead 130 coupled to the distal end of the at least one arm 124. The apparatus 120 may be fixed to a surface via the base 122. The at least one arm 124 may include a first arm 124a and a second arm 124b. The first arm 124a may extend from the base 122 and be rotatably coupled to the second arm 124b. The printhead 130 may be detachably and rotatably coupled to the distal end of the second arm 124b.

[0068] Device 120 can be any multi-axis device with at least four rotation axes. For example... Figure 1As seen, device 120 can be a multi-axis device with six rotation axes 126a-e. A first arm 124a can rotate 360 ​​degrees about a first axis 126a at interface 121, where it is coupled to a base 122. The first arm 124a may have a second axis 126b, which has a rotary joint 123 to adjust the height of the first arm 124a. The first arm 124a may have a third axis 126c at a connector 125, where the proximal end of the second arm 124b is rotatably coupled to the first arm 124a. Axis 126b provides bending and extension of the second arm 124b. The second arm 124b may have a fourth axis 126d that rotates the first portion 127 360 degrees. The second arm 124b may have a fifth axis 126e and a sixth axis 126f, each providing bending and extension of the second portion 128 of the second arm 126b. Those skilled in the art will understand that the multi-axis device 120 can be configured in various ways, including three or more rotational axes.

[0069] C. Printhead for multi-axis additive manufacturing equipment

[0070] The printhead 130 can be rotatably coupled to the distal end of the second arm 124b of the device 120. The printhead 130 can rotate 360 ​​degrees at the shaft 131.

[0071] i.2K printhead

[0072] like Figure 2 As seen, printhead 130 can be a 2K printhead 230. 2K printhead 230 can print various co-reactive compositions, such as the co-reactive compositions described above. Printhead 230 may include two pumping assemblies 220, each supplying a co-reactive component used in additive manufacturing. Each co-reactive component shares co-reactive chemistry with each other. These co-reactive components can be combined to form a printable co-reactive composition. 2K printhead 230 can be configured to print any of the printable compositions described in Section II using any of the printable co-reactive components discussed above.

[0073] The 2K printhead 230 may include two pumping assemblies 220, a mixing assembly 242, and a print nozzle 260. The printhead 230 may be rotatably coupled to the second arm 126b of the multi-axis assembly 120. Each of the two pumping assemblies 220 may be configured to dispense co-reactive components into the mixing assembly 242.

[0074] The co-reactive components can be mixed in the mixing assembly 242 to form a printable composition. The printable composition can be extruded from the mixing assembly 242 through the printing nozzle 260.

[0075] Each of the two pumping assemblies 220 may include a positive displacement pump, such as a screw pump 222. To prevent backflow, the screw pump 222 may be configured to resemble a screw. Due to the design of the screw pump 222, the flow can only move in the discharge direction as the co-reacting component is discharged. Additionally, the screw pump 222 may meter the flow rate to a given volumetric dosage. Alternatively, any canister, pen, or other co-reacting composition extruder may be used in the pumping assembly 220.

[0076] The 2K printhead 230 can be configured to dispense multiple co-reactive components from the two pumping assemblies 220 into a mixing assembly 242. The co-reactive components can be mixed in the mixing assembly 242 by static or dynamic mixing to form a printable composition. The static and dynamic mixing of the co-reactive components in the printhead 230 is substantially similar to the static and dynamic mixing in the multi-component printhead 330. These mixing methods are discussed in more detail below with reference to the multi-component printhead 330.

[0077] After the two co-reactive components are mixed in the mixing assembly 242 to produce a printable composition, the printable composition can be extruded from the mixing assembly 242 through the printing nozzle 260. The printing nozzle 260 can deposit the printable composition onto the first surface 113 of the printing surface 112, thereby forming a 3D object.

[0078] ii. Multi-component printhead

[0079] Printhead 130 can be a multi-component printhead 330, such as... Figure 3 As seen in the diagram. The multi-component printhead 330 can simultaneously and / or sequentially print multiple co-reaction compositions, such as the aforementioned co-reaction compositions, to achieve objects with a variety of physical properties (such as texture, elasticity, hardness, etc.). The versatility of the disclosed multi-component printhead offers the following benefits: increased printing speed of multiple compositions due to the elimination of printhead switching; reduced costs due to the need for a single device to print multiple compositions; and the ability for different printable compositions to combine in liquid form while being rapidly and continuously printed, thus reacting and solidifying at the boundaries between the compositions.

[0080] The printhead 330 of this application is designed to maintain a plurality of pumping assemblies 320 supplying the co-reactive components used in additive manufacturing, such as Figure 3 As seen in the diagram. Different co-reactive components share co-reactive chemical properties with each other. These co-reactive components can be combined to form printable co-reactive compositions. Each printable co-reactive composition is made from a combination of at least two of the co-reactive components. The multi-component printhead 330 is configured to print any of the printable compositions described in Section II using any of the co-reactive components discussed above.

[0081] The multi-component printhead 330 of this application may include at least three pumping components 320 and a mixing component 342. Figure 4 The multi-component printhead 330 may include a top mount 308 that supports each of at least three pumping assemblies 320 and detachably connects the additive manufacturing apparatus 330 to the multi-axis assembly 120. Each of the at least three pumping assemblies 320 may be configured to dispense a co-reactive component into a mixing assembly 342. Additionally, one of the at least three pumping assemblies 320 may include a flushing medium to be dispensed between printings of different printable compositions via the multi-component printhead 330. The multi-component printhead 330 may be configured to dispense a plurality of co-reactive components of the at least three pumping assemblies 320 into the mixing assembly 342. The co-reactive components may be mixed in the mixing assembly 342 to form a printable composition. The printable composition may be extruded from the mixing assembly 342 through the print nozzle 360. The print nozzle 360 ​​may deposit the printable composition to form a 3D object. Each of the components constituting the multi-component printhead 330 and the method of printing are discussed in more detail below.

[0082] a. Pumping assembly

[0083] At least three pumping assemblies 320 are detachably coupled to the diamond mount 340 of the multi-component printhead 330 of this disclosure. Each of the at least three pumping assemblies 320 is fluidly coupled to a source fluid of a corresponding co-reacting component. The corresponding co-reacting component is discharged through the distal end of each of the at least three pumping assemblies 320 into a fluid channel 334. The fluid channel is discussed in more detail below. Figure 5 As shown, the diamond mount 340 includes at least three orifices 336 that correspond to and receive the distal ends of at least three pumping assemblies 320. The diamond mount 340 can be configured to connect the distal ends of the at least three pumping assemblies 320 to a fluid channel 334, such that discharged co-reacting components flow from the at least three pumping assemblies 320 into the fluid channel 334. Mounting holes 346 can be arranged on the diamond mount 340 such that the diamond mount 340 is removably coupled to a top mount 308 to provide stability for the multi-component printhead 330. The at least three pumping assemblies 320 can be angled relative to axis A, such as... Figure 3 As can be seen in the image. Between the support of the top mount 308 and the support of the diamond mount 340 of the at least three pumping assemblies 320, the at least three pumping assemblies 320 are angled such that the distal end of each of the at least three pumping assemblies points toward axis A.

[0084] refer to Figure 3Each of at least three pumping assemblies 320 includes a positive displacement pump, such as a screw pump 322. To prevent backflow, the screw pump 322 may be configured to resemble a screw. Due to the design of the screw pump 322, the flow can only move in the discharge direction as the co-reacting component is discharged. Additionally, the screw pump 322 can meter the flow rate to a given volumetric dosage. Alternatively, any tubular, pen-type, or other co-reacting composition extruder can be used in the pumping assembly 320.

[0085] like Figures 3 to 5 As seen, the multi-component printhead 330 may include a first screw pump 322a, a second screw pump 322b, a third screw pump 322c, a fourth screw pump 322d, and a fifth screw pump 322e, each containing different co-reacting components. Although Figures 3 to 5 The configuration of five screw pumps 322 is illustrated, but it should be understood that the multi-component printhead 330 can be adapted to include four screw pumps, or alternatively, to include three screw pumps.

[0086] The first screw pump 322a may discharge the first co-reacting component in conjunction with the second screw pump 322b, which discharges the second co-reacting component. Similarly, the third screw pump 322c may discharge the third co-reacting component in conjunction with the fourth screw pump 22d, which discharges the fourth co-reacting component. The fifth screw pump 322e may discharge the fifth co-reacting component in conjunction with at least one of the first, second, third, or fourth screw pumps 322a-22d. Alternatively, any of the screw pumps 322 may include a flushing medium. For cleaning the additive manufacturing apparatus, flushing medium may be discharged from the screw pumps 322 between printing different printable compositions.

[0087] b. Hybrid Components

[0088] refer to Figure 4 A mixing assembly 342 is provided for a multi-component printhead 330. Located downstream of a pumping assembly 320 within the diamond mount 340, the mixing assembly 342 may include a mixing volume 332, at least three fluid channels 334, and a mixer 338. The at least three fluid channels 334 fluidly connect each screw pump in the screw pump 322 to the mixing volume 332. The configuration of the at least three fluid channels 334 can be adapted to any assembly such that discharged co-reactive components flow into the mixing volume 332 through the at least three fluid channels 334. The mixing volume 332 may be cylindrical or any other geometry adapted to capture the discharged co-reactive components. The geometry of the mixing volume 332 may depend on the nature or volume of the discharged co-reactive composition, or the available space within the diamond mount 340.

[0089] The timing of the arrival of co-reacting components in mixing volume 332 can affect the reaction between the co-reacting components. Residence time refers to the elapsed time between the entry of one co-reacting component into mixing volume 332 and the entry of another co-reacting component into mixing volume 332 to mix into a printable composition. The residence time between one co-reacting composition and another can be less than 5 seconds. A screw pump 322 containing co-reacting components included in a given printable composition dispenses the co-reacting components such that the co-reacting components are simultaneously present in mixing volume 332, or enter mixing volume 332 from channel 334 within at most 5 seconds of each other. Once in mixing volume 332, the co-reacting components can be statically or dynamically mixed together to form a printable composition.

[0090] For dynamic mixing, the mixing volume 332 can be a mixer 338, such as... Figure 4 The best-looking component is, for example, an impeller. Impeller 338 can be a helical element with threads that dynamically or statically mixes the co-reacting components when they enter the mixing volume 332. For dynamic mixing, impeller 338 can be connected to a motor, causing it to rotate within the mixing volume 332.

[0091] Dynamic mixing of the co-reaction composition by driving the impeller 338 can have certain advantages over static mixing. Generally, mechanical mixing yields a more thoroughly mixed co-reaction composition compared to static mixing (e.g., by the driving nature of the impeller 338). In this case, the size of the mixing volume 332 can therefore be relatively smaller than that required for static mixing, thereby reducing the overall size of the multi-component printhead 330 (e.g., reducing the size of the mixing volume 332). Since the amount of material retained within the multi-component printhead 330 (e.g., the amount of material between the pumping assembly 320 and the print nozzle 360) is reduced, thereby improving the particle size of pumping rate control, this relatively small size of the multi-component printhead 330 results in more stable printing.

[0092] Additionally, the reaction rate between the co-reacting components can be more easily controlled by driving the impeller 338. Specifically, the driving speed of the impeller 338 (e.g., the resulting revolutions per minute (RPM) of the impeller 338's spin) can be adjusted to achieve a target overall mixing rate. The RPM also affects the amount of material extruded from the print nozzle 360. Therefore, the RPM can be tuned to simultaneously influence both the degree of mixing and the extrusion rate, both of which affect the degree and rate of reaction of the co-reacting components.

[0093] Furthermore, the drive impeller 338 and the pumping assembly 320 can be controlled independently of each other. Therefore, both the RPM and the pumping rate can be independently tuned, and their combination can achieve any of the following: the desired degree of reaction of the co-reacting components, the target reaction rate of the co-reacting components, the residence time of the material in the mixing volume 332, and / or the extrusion rate of the co-reacting composition from the mixing volume 332.

[0094] The additive manufacturing apparatus 100 can hold the printable composition within a mixing volume for a period of time. This period of time can be 0 seconds, 1 second, 2 seconds, 3 to 5 seconds, 6 seconds, 7 seconds, or any range using any of the foregoing as an endpoint, such as 0 seconds to 7 seconds, 1 second to 6 seconds, 2 seconds to 5 seconds, or 3 seconds to 4 seconds. Holding the printable composition within the mixing volume ensures thorough mixing of the co-reactive components and produces a homogeneous printable composition.

[0095] c. Printing nozzle

[0096] The printable composition in mixing volume 332 is extruded through print nozzle 360. Print nozzle 360 ​​is removably coupled to stopper 362, which seals the distal end of mixing volume 332. Stopper 362 ensures that the printable composition does not leak from mixing volume 332. Print nozzle 360 ​​can be of various shapes to facilitate the extrusion of the printable composition.

[0097] d. Flushing medium

[0098] Once the printable composition is extruded from nozzle 360 ​​to form a 3D object, the user may want to change the type of printable composition extruded from additive manufacturing apparatus 360. To ensure that the mixing assembly 342 is free of previously printed printable composition, a flushing medium can be pumped through one of at least three pumping assemblies 320. The flushing medium can be a commercially available non-reactive medium configured to remove printable composition from the mixing assembly 342. The flushing medium can be a flowable non-reactive composition, such as, but not limited to, a hydrogel.

[0099] e. Methods for printing 3D objects using multi-component printheads

[0100] refer to Figure 6This illustrates an additive manufacturing method for printing 3D objects using a printhead 330. Method 600 includes a combination step 602, an extrusion step 604, a rinsing step 606, a combination step 608, and an extrusion step 610. In the combination step 602, a first co-reactive component and a second co-reactive component are combined in a mixing assembly. Prior to combination, the first and second co-reactive components may be held in corresponding pumping assemblies 320 of the printhead 330. To combine the first and second co-reactive components, components may be added to a mixing assembly 342 and mixed using an impeller 338. Once combined, the first and second co-reactive components can react to form a co-reactive composition or a first printable composition. Mixing parameters such as the time spent mixing, mixing speed, mixing apparatus, temperature, and / or pressure may vary depending on factors such as the amount and type of co-reactive components used, the volume of components in the mixture, the desired properties of the printable composition, the desired properties of the printed object, and the operating parameters or desired product parameters of any of the foregoing combinations. The first printable composition may be any of the printable compositions mentioned in Section II above.

[0101] The extrusion step 604 includes extruding a first printable composition from a mixing assembly through a print nozzle onto a print surface to form a 3D object. The print surface can be a print bed or any other material, such as... Figure 1 The first surface 113 of the printed surface 112 is shown. The speed at which the first printable composition is extruded from the mixing assembly can vary depending on the properties of the printable composition.

[0102] Printing of the second printable composition continues, and the rinsing step 606 includes rinsing the mixing assembly with a non-co-reactive component. The non-co-reactive component can be any commercially available rinsing medium. The rinsing medium can remain in the pumping assembly, similar to the first and second co-reactive components. The rinsing step 606 removes residual printable composition or previous co-reactive components from the mixing assembly, preventing further printable composition from being contaminated by previous co-reactive components or printable compositions.

[0103] During the combination step 608, the third and fourth co-reactive components are combined in a mixing assembly. The co-reactive components can be any of the co-reactive components mentioned in Section II above. Prior to combination, the third and fourth co-reactive components can be held in the corresponding pumping assembly 320 of the printhead 330. To combine the third and fourth co-reactive components, the components can be added to the mixing assembly 342 and mixed using the impeller 338. Once combined, the third and fourth co-reactive components react to form a second printable composition. Similar to the first printable composition, the mixing parameters can vary depending on the properties of the co-reactive components and the second printable composition. The second printable composition can also be any of the printable compositions mentioned in Section II above.

[0104] The extrusion step 610 includes extruding a second printable composition from the mixing assembly 342 through the printing nozzle 360 ​​onto the first surface 113 of the printing surface 112. The extrusion speed of the second printable composition from the mixing assembly 342 can vary depending on the properties of the printable composition. The second printable composition can be extruded onto a first printable composition that has already been deposited, such that the first and second printable compositions become a 3D printed object. The deposition speed of the second printable composition onto the first printable composition can be faster than the speed at which the first printable composition fully cures. If the first printable composition is not fully cured, the first and second printable compositions can react at the boundary between the first and second printable compositions to form a 3D printed object.

[0105] The printing of the printable composition continues, and method 600 may optionally include a second rinsing step 612. Rinsing step 612 may include rinsing the mixing component 342 with a rinsing medium, similar to rinsing step 606. Furthermore, method 600 may optionally be repeated to fully complete the desired 3D printed object. 3D objects printed using method 600 may include multiple printable compositions printed rapidly and continuously from printhead 330. By rinsing the mixing component 342 between printing different printable compositions, method 600 can print different printable compositions free from contaminants from each printable composition.

[0106] 3D printed objects created using method 600 can be made from a variety of printable compositions. Due to the speed at which method 600 prints multiple printable compositions, the final 3D printed object can be made from printable compositions that react with each other to form a multi-printable composition 3D object.

[0107] This disclosure provides a second method for printing using printhead 330.

[0108] refer to Figure 7This illustrates an additive manufacturing method for printing 3D objects using a printhead 330. Method 700 includes a combination step 702, an extrusion step 704, a combination step 706, and an extrusion step 708. In the combination step 702, a first co-reactive component and a second co-reactive component are combined in a mixing assembly 342. The co-reactive component can be any of the co-reactive components mentioned in Section II above. Prior to combination, the first and second co-reactive components can be held in corresponding pumping assemblies 320 of the printhead 330. To combine the first and second co-reactive components, components are added to the mixing assembly 342 and mixed using an impeller 338. Once combined, the first and second co-reactive components react to form a first printable composition. Mixing parameters such as the time spent mixing, mixing speed, mixing apparatus, temperature, and / or pressure can vary depending on factors such as the amount and type of co-reactive components used, the volume of components in the mixture, the desired properties of the printable composition, the desired properties of the printed object, and the operating parameters or desired product parameters of any of the foregoing combinations. The first printable composition can be any of the printable compositions mentioned in Section II above.

[0109] The extrusion step 704 includes extruding a first printable composition from the mixing assembly 342 through the printing nozzle 360 ​​onto a first surface 113 of the printing surface 112 to form a 3D object. The printing surface 112 may be a print bed or any other material. The speed at which the first printable composition is extruded from the mixing assembly may vary depending on the properties of the printable composition.

[0110] In the combination step 706, the third co-reacting component is combined with the first co-reacting component in a mixing assembly. The co-reacting component can be any of the co-reacting components mentioned in Section II above. Prior to combination, the third co-reacting component can be held in the pumping assembly 320 of the printhead 330. Each of the pumping assemblies 320 of the printhead 330 may contain a co-reacting component. The first co-reacting component can react with each of the other co-reacting components to form different printable compositions. That is, each co-reacting component reacts with the first co-reacting component to form a corresponding printable composition. The first, second, third, fourth, and fifth co-reacting components can be held in the corresponding pumping assemblies.

[0111] Referring back to step 706, to combine the first and third co-reactive components, the components may be added to the mixing assembly and mixed using impeller 338. Once combined, the first and third co-reactive components react to form a second printable composition. Similar to the first printable composition, the mixing parameters may vary depending on the properties of the co-reactive components and the second printable composition. The second printable composition may also be any of the printable compositions mentioned in Section II above.

[0112] The extrusion step 708 includes extruding a second printable composition from the mixing assembly 342 through the printing nozzle 360 ​​onto a first surface 113 of the printing surface 112 to form a 3D object. The printing surface 112 can be a print bed or any other material. The speed at which the first printable composition is extruded from the mixing assembly 342 can be varied depending on the properties of the printable composition.

[0113] A second printable composition can be extruded onto a first printable composition that has already been deposited, so that the first and second printable compositions become a single 3D printed object. The second printable composition can be deposited onto the first printable composition faster than the first printable composition can fully cure. If the first printable composition is not fully cured, the first and second printable compositions can react at the boundary between them to form a 3D printed object.

[0114] Method 700 may optionally include a rinsing step 710, which includes rinsing the mixed assembly with a non-co-reactive component. The non-co-reactive component may be the rinsing medium previously described. Rinsing step 710 removes any residual printable composition or previously used co-reactive component from the mixed assembly, preventing further printable composition from being contaminated by the previously used co-reactive component or printable composition. Step 710 is not mandatory but may be included as needed. Additionally, method 700 may optionally be repeated to form a multi-printable composition 3D object.

[0115] IV. Printing 3D Objects

[0116] The multi-axis additive manufacturing apparatus 120 and rotary print bed 110 disclosed herein allow for the printing of a variety of different 3D objects. To achieve different thicknesses of printing material during the formation of the 3D object 10, the flow rate of the co-reaction composition and the movement speed of the print arm can be varied. During printing, the flow rate and movement speed of the print arm can be kept proportional to each other to form print lines of uniform thickness. To change the thickness of the print lines, the flow rate and movement speed of the print arm can be changed independently of each other.

[0117] A. Support structure and orientation of 3D objects during printing

[0118] By rotating and tilting the print bed 110 and the multi-axis additive manufacturing apparatus 120, 3D objects can be printed without the use of support structures. For example... Figure 8AAs seen, when printing a 3D object 10 using a fixed print bed 20 and / or a 3D printing apparatus without more than three moving axes 30, the 3D object 10 can be printed with a support structure 16. When the apparatus 30 prints the object 10 from the bottom portion 11a to the top portion 11b, the overhang 14 will be pulled downwards towards the ground 101 due to gravity. To prevent the overhang 14 from falling and sagging, the apparatus 30 can print a support structure 16. Any dripping or sagging in the portion of the printed object 10 forming the overhang 14 may alter the shape of the printed object 10.

[0119] like Figure 8B As shown, the multi-axis additive manufacturing apparatus 120 and rotary print bed 110 of this application can print by rotating / tilting the print bed 110 and rotary print head 130 of the multi-axis additive manufacturing apparatus 120 at an angle that avoids the dripping of the co-reactive composition that would allow for extrusion, thereby printing 3D objects without a support structure. Progressive series Figures 9A to 9E This demonstrates a method for printing 3D objects with overhangs without a supporting structure.

[0120] To print 3D objects without a supporting structure, the printing bed can rotate and tilt so that the printed portion of the 3D object 10 is always parallel to the ground 101, and the base 114 of the printing bed 110 can be fixed to the ground. (Reference) Figures 9B to 9E As can be seen, a 3D-printed object 10 has a first portion 90 and a second portion 92 including a cantilever portion 14. Line X depicts the layers of the printed object 10 in each of the progressive diagrams. Figures 9B to 9C The first portion 90 can be printed along line X. The first portion 90 is parallel to the printing surface 112 of the print bed 110 and the base 114 of the print bed 110 can be fixed to its ground 101. The additive manufacturing system 100 can extrude the co-reactive composition from the print head 130 of the device 120 without rotating or tilting the printing surface 112 of the print bed 110. The printing speed of the co-reactive composition can be reduced to allow each layer to cure before printing the next layer to avoid sagging. Too high an interlayer printing speed may cause partially cured layers to sagging or bend under the weight of the newly printed layer.

[0121] The second portion 92 of object 10 includes a cantilever portion 14. When printing the second portion 92 of object 10, to prevent the portion 92 from sagging / dripping, the additive manufacturing system 100 can tilt the printing surface 112 of the print bed 110 to orient the printing of object 10, such that the second portion 92 is parallel to the base 114 of the print bed 110, which can be attached to its ground surface 101. Figures 9D to 9E As shown, when the printing line X travels to the second section 92, the printing surface 112 of the printing bed 110 is tilted at a certain angle relative to the ground 101 to avoid the use of a support structure.

[0122] B. Impossible geometric shapes

[0123] Printing 3D objects using devices with three or fewer axes and / or fixed print beds can result in reduced range of motion and potential limitations on the geometry of printable 3D shapes. (Reference) Figures 10A to 10B The diagram shows two 3D objects 60 and 70. It may be necessary to print the interface surface 50 located between objects 60 and 70. The device 30 has three or fewer axes of rotation. When the device 30 attempts to print along the interface surface 50, due to the physical size of the print head and the lack of rotational capability, there is a portion of the surface 50 that the device 30 cannot reach without hitting either object 60 or object 70. The device 30 may attempt to print along the bottom portion 51 of the interface surface 50. Because the device 30 has three or fewer axes, when the device 30 attempts to print along the bottom portion 51 of the interface 50, the side surface 31 of the device 30 may face the risk of impacting object 70 along its edge 71. Due to the impact on edge 71 by surface 31, the device 30 may be unable to print along the interface surface 50.

[0124] like Figure 10B As seen herein, the additive manufacturing apparatus 120 of this disclosure can rotate on multiple axes, thereby orienting the print head 130 in multiple positions. When printing along the interface 50 between object 60 and object 70, the apparatus 120 can use its multiple axes of rotation to adjust the angle of the print head 130 to allow printing along the surface 50 without touching object 60 or object 70. Due to the degrees of freedom of multi-axis rotation, the apparatus 120 can have a greater number of achievable geometries compared to apparatuses with fewer axes of rotation.

[0125] C. Rotation of the device and rotation of the printing bed

[0126] Additive manufacturing system 100 may involve simultaneously controlling multiple axes of additive manufacturing apparatus 120 and print bed 110. Coordination of all axes of system 100 can increase the complexity of printing in repetitive motions, such as printing repetitive vertically displaced concentric circles to form a cylindrical 3D printed object. A first method of printing such a cylindrical object 10 may include printing along a line of printing motion 17 in vertically displaced concentric circles by using a manipulating device 120 with multiple axes 126a-f. A second method of printing object 10 of the present disclosure may include fixing print head 130 in place and rotating print bed 110 along axis 111a such that print surface 112 is rotated 360 degrees below print head 130. When printing each circular layer of object 10, apparatus 120 may use an axis to move the print nozzle 160 of print head 130 vertically upward to begin printing the next circular layer. As the number of axes to be coordinated during printing decreases, the second printing method can complete the printing of object 10 faster than the first method.

[0127] D. Fixed Printing and Conformal Printing

[0128] Traditional stationary printing is a 3D printing method that involves depositing a printable composition layer by layer to form a 3D printed object. For example... Figure 12A As seen, by using fixed printing, the curves 18 of object 10 can be printed layer by layer. Because each layer is printed separately, each layer 19 can produce texture boundaries between the next layer. The additive manufacturing system 100 can use fixed printing to print 3D objects.

[0129] like Figure 12B As seen in the diagram, conformal printing is a 3D printing method that involves moving a print head along the curve of the 3D printed object while depositing a printable composition, as opposed to layer-by-layer printing. By moving along the curve of the object, conformal printing can reduce boundary lines due to the fewer layers required. Figure 12B As seen in the present disclosure, the additive manufacturing system 100 can use conformal printing to print 3D objects by moving the print head 130 along the curve 18 of the 3D printed object 10 via multiple axes 126 of the manipulator 120.

[0130] IV. Software for printing 3D objects

[0131] like Figure 14 As shown, the computer system 1400 may include one or more processors 1410 and computer-executable instructions stored on a computer storage medium 1420. When executed, the computer-executable instructions (also referred to as "3D printing software 1430") configure the computer system 1400 to control the additive manufacturing system 100. The computer-executable instructions are capable of controlling any electronic features of the additive manufacturing system.

[0132] Computer-executable instructions can control actuators, such as motors, to move and position the arm 124 of the additive manufacturing system 100. For example, as... Figure 1 As shown, a motor can be integrated with each of shafts 126a-e. Computer-executable instructions can cause the motor to actuate arm 124 to a desired position at a desired speed. Similarly, computer-executable instructions can cause one or more actuators connected to print bed 110 to rotate, tilt, or otherwise move print surface 112. Additionally, computer-executable instructions can control pumping assembly 220 and mixing assembly 242 within additive manufacturing system 100.

[0133] The 3D printing software application 1430 may include various modules that enable the additive manufacturing system 100 to print the desired 3D object 10. As used herein, a “module” includes computer-executable code and / or computer hardware performing a specific function. Those skilled in the art will understand that the differences between different modules are at least partly arbitrary, and modules may be otherwise combined and divided and still remain within the scope of this disclosure. Therefore, components are described as “modules” only for clarity and explanation, and should not be construed as indicating any particular structure requiring computer-executable code and / or computer hardware unless otherwise expressly stated.

[0134] The motor control module 1440 can be configured to control various actuators within the additive manufacturing system 100. The motor control module 1440 can communicate directly with one or more actuators and / or one or more motor controllers. The motor control module 1440 can utilize public and private application programming interfaces (APIs) associated with the motor controllers. Furthermore, the motor control module 1440 is capable of operating with various types and models of actuators, allowing the additive manufacturing system 100 to be updated or retrofitted with different motors still controllable by the motor control module 1440.

[0135] The 3D object module 1450 can be configured to receive and / or analyze instruction files used to create the 3D object 10. The instruction files may include computer-aided design (CAD) files, g-code files, or any other files capable of containing information required for printing the 3D object 10. The 3D object module 1450 can be configured to create or adjust one or more toolpaths for printing the 3D object 10. Additionally, one or more toolpaths can be created in conjunction with the programmed movement of the print surface 112. For example, the 3D object module 1450 can be configured to create or adjust toolpaths and print surface 112 movement for overhangs, tapered surfaces, interfaces between different types of co-reacting compositions, and other similar areas in the 3D object 10.

[0136] The chemical composition module 1460 can be configured to receive and / or analyze information related to co-reactive components and fillers to be used for and / or used in printing the 3D object 10. The chemical composition module 1460 can automatically or manually receive information about each co-reactive component connected to the pumping assembly 220. For example, a user can manually type information indicating which co-reactive component is connected to which pumping assembly 220. Additionally or alternatively, each container of co-reactive components can be associated with an RFID chip, an integrated memory chip, or other electronic devices configured to automatically and electronically share information indicating which co-reactive component is connected to which pumping assembly 220.

[0137] The chemical composition module 1460 can also access a database or lookup table stored in the computer storage medium 1420. The database may include information describing the physical and chemical properties of each co-reaction component, co-reaction composition, and / or additive / filler. For example, each of the components described in Tables 1 and 2 above can be more fully characterized experimentally to determine the resulting viscosity, curing speed, and other properties based on the ratio of different components, the temperature at which they are mixed, the mixing rate, the humidity at which they are mixed, and / or various other physical and chemical properties of each co-reaction component, co-reaction composition, and / or additive / filler.

[0138] Using a motor control module 1440, a 3D object module 1450, and a chemical composition module 1460, 3D printing software 1430 controls the additive manufacturing system 100. Specifically, the 3D printing software 1430 can automatically and dynamically adjust the printing of the 3D object 100 based on its structure and the characteristics of the co-reaction composition and / or additives / fillers. For example, the 3D printing software 1430 can receive a 3D object 100 including overhangs. The 3D object module 1450 can identify the path the nozzle will travel as it extrudes the layers that will construct the overhangs. The chemical composition module 1460 can also identify the viscosity and curing rate of the co-reaction composition to be used for printing the overhangs. For example, the chemical composition module 1460 can provide viscosity information to the 3D object module 1450. The 3D object module 1450 can determine an extrusion rate threshold that the nozzle cannot exceed without the risk of overhang sagging. Using this information, the motor control module 1440 can move the arm at a specific speed and the pumping component 220 can pump the co-reaction components at a specific speed, while printing the overhanging portion of the 3D object 10.

[0139] Additionally or alternatively, the motor control module 1440 may tilt the printing surface 112 in a direction that reduces the angle of the overhang relative to the direction of gravity. The motor control module 1440 may then move the nozzle and / or printing surface 112 at a speed that takes into account both the viscosity of the co-reactive composition and the curing time of the co-reactive composition. For example, the nozzle and / or printing surface 112 may move at a speed that prevents the viscosity of the co-reactive composition from dripping, and also allows the co-reactive composition to at least partially cure to a level that allows the overhang to maintain its correct shape as defined by the instruction file used to create the 3D object 10.

[0140] Furthermore, these methods can be practiced by a computer system comprising one or more processors and computer-readable media such as computer memory. Specifically, the computer memory may store computer-executable instructions that, when executed by one or more processors, cause various functions to be performed, such as the actions described in the embodiments.

[0141] The functionality of a computing system can be enhanced by its ability to interconnect with other computing systems via network connections. Network connections may include, but are not limited to, connections via wired or wireless Ethernet, cellular connections, or even computer-to-computer connections via serial, parallel, USB, or other connections. These connections allow the computing system to access services on other computing systems and to receive application data from other computing systems quickly and efficiently.

[0142] The interconnection of computing systems has facilitated distributed computing systems, such as so-called "cloud" computing systems. In this specification, "cloud computing" can refer to a system or resource that enables ubiquitous, convenient, on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, and services), which can reduce management effort or service provider interaction in configuring and deploying these resources. Cloud models can consist of various features (e.g., on-demand self-service, widespread network access, resource pooling, rapid elasticity, measurement services, etc.), service models (e.g., Software as a Service ("SaaS"), Platform as a Service ("PaaS"), Infrastructure as a Service ("IaaS")), and deployment models (e.g., private cloud, community cloud, public cloud, hybrid cloud, etc.).

[0143] Cloud-based and remote service applications are common. Such applications are hosted on public and private remote systems (such as the cloud) and typically provide a set of web-based services for communicating back and forth with clients.

[0144] Many computers are designed to be used through direct user interaction. Therefore, computers have input hardware and software user interfaces to facilitate user interaction. For example, modern general-purpose computers may include a keyboard, mouse, touchpad, camera, etc., to allow users to input data into the computer. In addition, various software user interfaces can be used.

[0145] Examples of software user interfaces include graphical user interfaces, text-based command-line user interfaces, function key or hotkey user interfaces, etc.

[0146] The computer system described may include or utilize a special-purpose or general-purpose computer including computer hardware, as discussed in more detail below. The computer system also includes physical and other computer-readable media for carrying or storing computer-executable instructions and / or data structures. Such computer-readable media may be any available media accessible by a general-purpose or special-purpose computer system. Computer-readable media storing computer-executable instructions are physical storage media. Computer-readable media carrying computer-executable instructions are transmission media. Therefore, by way of example and not limitation, embodiments of the invention may include at least two distinct types of computer-readable media: physical computer-readable storage media and transmission computer-readable media.

[0147] Physical computer-readable storage media include RAM, ROM, EEPROM, CD-ROM or other optical disc storage (e.g., CD, DVD, etc.), magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of computer-executable instructions or data structures and that can be accessed by a general-purpose or special-purpose computer.

[0148] A “network” is defined as one or more data links that enable the transmission of electronic data between computer systems and / or modules and / or other electronic devices. When information is transmitted or provided to a computer via a network or another communication connection (wired, wireless, or a combination of wired and wireless), the computer appropriately regards that connection as a transmission medium. The transmission medium may include networks and / or data links, which can be used to carry program code, represented in the form of computer-executable instructions or data structures, and accessible by general-purpose or special-purpose computers. Combinations of the above are also included within the scope of computer-readable media.

[0149] Furthermore, upon arrival at various computer system components, program code in the form of computer-executable instructions or data structures can be automatically transferred from a transmission computer-readable medium to a physical computer-readable storage medium (or vice versa). For example, computer-executable instructions or data structures received via a network or data link can be cached in RAM within a network interface module (e.g., a "NIC") and then ultimately transferred to the computer system RAM and / or a low-volatility computer-readable physical storage medium at the computer system. Therefore, computer-readable physical storage media can be included in computer system components that also (or even primarily) utilize transmission media.

[0150] Computer-executable instructions include, for example, instructions and data that cause a general-purpose computer, a special-purpose computer, or a special-purpose processing device to perform a particular function or group of functions. For example, computer-executable instructions can be, for example, binary numbers, intermediate format instructions (such as assembly language), or even source code. Although the subject matter has been described in language specific to structural features and / or methodological actions, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the features or actions described above. Rather, the described features and actions are disclosed as exemplary forms for implementing the claims.

[0151] Those skilled in the art will understand that computer-executable instructions can be executed in networked computing environments with various types of computer system configurations, including personal computers, desktop computers, laptop computers, message processors, handheld devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, microcomputers, mainframes, mobile phones, PDAs, pagers, routers, switches, etc. Computer-executable instructions can also be practiced in distributed system environments, where tasks are executed on both local and remote computer systems connected by network links (via hardwired data links, wireless data links, or a combination of hardwired and wireless data links). In a distributed system environment, program modules can be located in both local and remote memory storage devices.

[0152] Alternatively or additionally, the functionality described herein may be performed at least in part by one or more hardware logic components. For example, but not limited to, illustrative types of hardware logic components that may be used include field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), application-specific standard products (ASSPs), system-on-a-chip (SoCs), complex programmable logic devices (CPLDs), etc.

[0153] Example

[0154] The aspects of this disclosure are further illustrated by reference to the following examples. It will be apparent to those skilled in the art that many modifications can be made to the materials and methods without departing from the scope of this disclosure.

[0155] Examples of printing methods using multi-component printheads

[0156] Example 1 – Online Composition Changes Using ARE 3D Printing

[0157] Dissimilar formulations are loaded into each of five progressive pumps to allow two distinct thermosetting compositions to be printed into a single 3D printed part. To print the first composition, a first amine formulation (formulation A) is loaded into pump 1, and a first isocyanate formulation (formulation E) is loaded into pump 2. The first segment of the part is printed by metering the formulations from pumps 1 and 2 at a fixed volume ratio through a mixer to produce the first thermosetting composition. The first composition is deposited on the print bed along a predefined toolpath until the partial segment is complete. The print head is then moved to a defined cleaning or rinsing position. A cleaning compound loaded in pump 3 is then metered through the mixer to remove all of the first composition from the print head. Once rinsing is complete, the print head returns to the area on the print bed where the second segment of that part will be printed. The second segment is printed by metering the second amine formulation (formulation B) from pump 4 and the second isocyanate formulation (formulation F) from pump 5 at a fixed volume ratio through the mixer to produce the second thermosetting composition. The second composition is deposited on the print bed along a predefined toolpath to work in conjunction with the first segment to complete the final part. The final multi-component part is allowed to cure at 71°C for 48 hours.

[0158] Example 2 – On-Demand Material Performance Tuning Using ARE 3D Printing

[0159] Different formulations are loaded into five progressive pumps to allow for on-demand adjustment of the material properties of the 3D printed parts. Isocyanate formulation E is loaded into pump 1, and amine formulations AD are loaded into pumps 2-5, respectively. At the start of printing, a first segment is printed by metering formulation AD relative to formulation E at a defined volume ratio via a mixer to produce a first thermosetting composition with known material properties. At the end of the first segment, a second segment is printed by changing the metering ratio of formulation AD relative to formulation E, thereby producing a second thermosetting composition with different material properties than the first thermosetting composition. This process is repeated twice more to create third and fourth thermosetting compositions for the third and fourth segments of the printed part. This results in a single 3D printed article with four segments, each with different material properties. The final part is allowed to cure at 71°C for 48 hours.

[0160] Example 3 – Printing 3D Objects Using Multi-Axis Additive Manufacturing

[0161] Different formulations are loaded into each of five progressive pumps to allow two distinct thermoset compositions to be printed into a single 3D printed part. To print the first composition, a first amine formulation (formulation A) is loaded into pump 1, and a first isocyanate formulation (formulation E) is loaded into pump 2. The print bed is oriented in a first configuration, and the first composition is deposited on the print bed along a predefined toolpath until a partial segment is completed under different printing conditions. The print bed is reoriented to a second configuration that is not parallel to the first position. The first composition is deposited on the print bed along a predefined toolpath until a partial segment is completed. Once flushing is complete, the print head returns to the area on the print bed where a second segment of that part will be printed. The print head angle is changed. To print the second composition, a second amine formulation (formulation B) is loaded into pump 1, and a first isocyanate formulation (formulation D) is loaded into pump 2. The print head angle is rotated to allow contact with the portion, and the second composition is deposited on the print bed along a predetermined toolpath until a partial segment is completed under different printing conditions. The multi-material composition with overhangs allows for curing at 71°C for 48 hours.

Claims

1. A method for printing 3D articles, the method comprising: A first co-reactive component and a second co-reactive component are combined in a mixing assembly of a printhead connected to a multi-axis movable manipulator, wherein the first co-reactive component and the second co-reactive component react to form a first printable composition; The print head is moved while the first printable composition is extruded to print a first portion of the 3D printed article onto a print bed, wherein the print bed is disposed in a first orientation, and wherein the first portion of the 3D printed article is printed along a first axis. Move the printing bed to a second orientation that is not parallel to the first orientation; as well as The print head is moved while the first printable composition is extruded to print a second portion of the 3D printed article onto the first portion of the 3D printed article, wherein the second portion of the 3D printed article is printed along a second axis that is not parallel to the first axis.

2. The method of claim 1, wherein the mixing component comprises a mechanical mixer.

3. The method according to any one of claims 1 to 3, further comprising: The third co-reactive component and the fourth co-reactive component are combined in the mixing assembly, and the third co-reactive component and the fourth co-reactive component react to form a second printable composition.

4. The method of claim 3, further comprising: The printing bed is moved to a third orientation that is not parallel to at least one of the first and second orientations.

5. The method of claim 4, further comprising: The print head is moved while the second printable composition is extruded to print a third portion of the 3D printed article onto one of the first or second portions of the 3D printed article, wherein the third portion of the 3D printed article is printed along a third axis, wherein the third axis is not parallel to the first or second axis.

6. The method according to any one of claims 1 to 5, wherein the printing bed is moved to the first orientation such that the first axis is oriented perpendicular to the ground surface, and the printing bed is moved to the second orientation such that the second axis is oriented at an angle not parallel to the ground surface.

7. The method of claim 3, wherein the first printable composition and the second printable composition each comprise: A filler comprising 1 wt.% to 20 wt.% of the total weight of the composition; and The solvent is present in an amount of less than 5 wt.% of the total weight of the composition; The first printable composition and the second printable composition each comprise a thermosetting composition, and are characterized by a viscosity of 5,000 cP to 5,000,000 cP measured using a rheometer with a gap of 1 mm to 2 mm, and a viscosity of 0.1 s at 25°C. -1 The shear rate is 0.

1.

8. The method according to any one of claims 1 to 7, wherein the printhead moves at a speed determined at least in part based on the physical or chemical properties of the first printable composition.

9. An additive manufacturing system for printing 3D objects, the additive manufacturing system comprising: A multi-axis movable manipulator, the multi-axis movable manipulator comprising: Base, the base being fixed to the surface; A first arm, which is rotatably connected to the base; A second arm, rotatably connected to the first arm at its proximal end; and A printhead, which is rotatably coupled to the distal end of the second arm; The first and second arms are each configured to rotate about different rotation axes, such that the multi-axis movable manipulator can move along at least four rotation axes; and A tiltable and rotatable printing bed, the printing bed comprising: A base, which is fixed to an anchoring surface; A printing surface, which is connected to the base; The printing surface is configured to tilt between a horizontal and a non-horizontal position and also rotate about an axis.

10. The additive manufacturing system of claim 9, wherein the multi-axis additive manufacturing apparatus is spaced at a predetermined distance from the tiltable and rotatable print bed, such that the print head can be oriented to interact with the print surface.

11. The additive manufacturing system according to any one of claims 9 to 10, wherein the printhead comprises a 2K printhead, the 2K printhead comprising: Two pumping assemblies, each of which is configured to dispense a corresponding printable component; A mixing assembly, fluidly coupled to the two pumping assemblies, comprising: Mixed volume; Two fluid channels, each of which is fluidly connected to one of the two pumping assemblies, and the corresponding printable component dispensed by each of the two pumping assemblies flows into the mixing volume through the fluid channels fluidly connected to the pumping assemblies; and A mechanical mixer, positioned within the mixing volume, configured to mechanically mix the printable components dispensed from the two pumping assemblies; and A printing nozzle, fluidly coupled to the mixing assembly, is configured to extrude the printable component during an additive manufacturing process.

12. The additive manufacturing system of claim 11, wherein each of the two pumping assemblies comprises a screw pump, each of the screw pumps being fluidly coupled to a source of the respective printable component.

13. The additive manufacturing system of claim 9, wherein the printhead comprises a multi-component printhead, the multi-component printhead comprising: At least three pumping assemblies, each of which is configured to dispense a corresponding printable component; A mixing assembly, fluidly coupled to each of the at least three pumping assemblies, the mixing assembly comprising: Mixed volume; At least three fluid channels, each of which is fluidly coupled to one of the at least three pumping assemblies, and the corresponding printable component dispensed by each of the at least three pumping assemblies flows into the mixing volume through the fluid channels fluidly coupled to the pumping assemblies; and A mechanical mixer, positioned within the mixing volume, configured to mechanically mix the printable components dispensed from the at least three pumping assemblies; and A printing nozzle, fluidly coupled to the mixing assembly, is configured to extrude the printable component during an additive manufacturing process.

14. The additive manufacturing system of claim 13, wherein at least two of the printable components dispensed by at least two of the at least three pumping components include co-reactive components that react under ambient conditions during the additive manufacturing process.

15. The additive manufacturing system of claim 13 or claim 14, wherein each of the at least three pumping assemblies is assigned a different printable component.

16. The additive manufacturing system according to any one of claims 9 to 15, wherein the at least three pumping assemblies comprise five pumping assemblies.

17. The additive manufacturing system of claim 15 or claim 16, wherein each of the different printable components comprises a first co-reactive component, a second co-reactive component, a third co-reactive component, and a fourth co-reactive component, and The first co-reacting component and the second co-reacting component react to form a first co-reacting composition, and the third reacting component and the fourth reacting component react to form a second co-reacting composition different from the first co-reacting composition.

18. The additive manufacturing system of claim 17, wherein the first pumping assembly and the second pumping assembly that discharges the second co-reacting component cooperate in discharging the first co-reacting component.

19. The additive manufacturing system according to any one of claims 17 to 18, wherein the third pumping assembly and the fourth pumping assembly discharging the fourth co-reactive component cooperate in discharging the third co-reactive component.

20. The additive manufacturing system according to any one of claims 9 to 19, wherein one of the printable components discharged by the at least three pumping assemblies comprises a flushing medium.

21. The additive manufacturing system of claim 20, wherein the rinsing medium is discharged into the mixing assembly, and residual one or more printable components present in the mixing assembly are discharged.

22. The additive manufacturing system according to any one of claims 9 to 21, wherein the tiltable and rotatable print bed is configured to orient the print surface such that the printable composition extruded from the print head onto the print surface is at least partially cured parallel to the anchoring surface.

23. The additive manufacturing system according to any one of claims 9 to 22, further comprising: One or more processors; as well as One or more computer-readable media, wherein executable instructions are stored thereon, the executable instructions, when executed by the one or more processors, configuring the additive manufacturing system to: The generation command moves the printhead at a speed determined at least in part based on the physical or chemical properties of the printable component.

24. The method according to any one of claims 1 to 8, wherein it is performed using the additive manufacturing system according to any one of claims 9 to 23.

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