3d printer with printing composite plastics and plastic metal and plastic ceramic composite capability

Abstract

The 3D printer (10) may include a frame, at least one panel (11, 13, 14, 19) removably attached to the frame and defining a printing shell, a heated build chamber within the printing shell, and a heated print bed defining the bottom of the heated build chamber.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 597,545, filed November 9, 2023, and U.S. Provisional Patent Application No. 63 / 601,510, filed November 21, 2023. The entire contents of each of these applications are incorporated herein by reference. Technical Field

[0003] This disclosure relates to the field of additive manufacturing of various thermoplastics, plastic-ceramics, metals and hybrid metal-plastic structures, polymers, composites and / or other materials. In particular, this disclosure relates to a large-scale, versatile, cost-effective 3D printer and its components, including custom firmware and software, configured to achieve high-quality printing and allow the use of various additive manufacturing input file formats.

[0004] This may include, but is not limited to, heated print beds, 3D printers including such heated print beds, methods of manufacturing such heated print beds, and / or 3D printers including heated enclosures that surround a printing environment capable of maintaining high temperatures. Background Technology

[0005] 3D printing, often referred to as additive manufacturing, plays a key role in the Industry 4.0 revolution, representing the integration of advanced digital technologies with manufacturing processes. Originating in the 1980s, 3D printing was invented by creating 3D objects layer by layer using a technique called photopolymerization. With increasing interest in the technology, various 3D printing techniques have been developed, such as selective laser sintering (SLS) and fused deposition modeling (FDM), diversifying the capabilities of this revolutionary technology.

[0006] In today's world, 3D printing is used in a wide range of applications, from food preparation to bioprinting and healthcare. This adaptation of 3D printing technology across multiple fields has led to the use of new / novel materials (depending on the application) and production characteristics that comply with national / international standards. The choice and physical form of the raw materials used in a 3D printer (print feed) largely depend on the final application of the finished product, which in turn determines the customized nature of the 3D printer.

[0007] With the recent penetration of 3D printing technology into aerospace, automotive, healthcare, and consumer electronics, the search for suitable (robust yet lightweight) printing feedstocks has led to the use of various metal-plastic composites. These hybrid composites allow for the customization of materials with specific properties, making them valuable for industries that require the performance and efficiency of their products. The physical dimensions of the final printed part determine the dimensions of the different components of a 3D printer. While off-the-shelf 3D printers are available for hobbyists, industrial applications require a complete redesign of individual 3D printer blocks to ensure the quality of the final product being produced.

[0008] 3D printers, especially those utilizing fused deposition modeling (FDM) or fused filament fabrication (FFF) technologies, are well documented in the art. The printing process of such devices involves heating the printing feed material, propelling it through heated nozzles, and assembling it layer by layer until a 3D object is produced on a temperature-controlled print bed. Because the printing process involves the sequential placement of layers, the success and quality of a print job depend on the ability to maintain alignment between the object and the extruder nozzles, ensuring that the entire model aligns itself with the appropriate 3D model.

[0009] The final result of a 3D printer largely depends on proper adhesion between the object being printed and the printing surface (often called the print bed). Traditional FDM-based 3D printers use print beds primarily made of materials such as metal, glass, and acrylic. Improper adhesion of the initial layer can lead to a warped design, resulting in poor-quality prints. Conventional 3D printers involve using a heat-resistant polyimide film to hold the base layer to the print bed during the printing process to ensure proper alignment. Some applications require gradually cooling feedstock (acrylonitrile butadiene styrene, ABS), necessitating the use of a heated print bed with the ability to maintain a desired high temperature on the print bed surface and to allow for gradual and controlled cooling.

[0010] In the most widely used industrial-grade 3D printers, Fused Deposition Modeling (FDM) or Fused Filament Fabrication (FFF) technology is generally used as the preferred method for filament deposition. Fused Particle Fabrication (FGF) is a newer technology, also known as fused particle manufacturing or particle 3D printing, based on extrusion 3D printing technology, which uses solid (usually plastic) granules as feedstock instead of filaments. FGF involves heating solid granules / pellets made of a special material and extruding the molten material onto the printing surface. Subsequent layering of the molten filament produces the final product desired by the user. The melting process occurs in a controlled manner, where the temperature of the 3D printer and the extrusion rate are regulated by a computer-aided program to ensure that the user's quality and design requirements are met. Among the many extruders reported in the prior art, screw-based extrusion units are widely used due to their ability to handle different material types, provide consistent material flow, and offer higher output rates.

[0011] For a given print feed using particulate material, the quality (and finishing) of the final product depends heavily on the environmental conditions under which the printing takes place. Specifically, using high-temperature materials in extrusion-based 3D printers necessitates maintaining a specific temperature during the printing process. This prevents rapid cooling of the printed layers, promotes layer adhesion, and reduces the brittleness of the final design. An insulating enclosure, often called a heated build chamber, is typically formed around the stage to maintain the required temperature during printing. Depending on the final print size, variations in the heated build chamber provide isolation and facilitate product finishing and curing processes.

[0012] Some of the most common drawbacks in existing technologies include inconsistent adhesion of polyimide films / masking tapes when used in heated print bed designs, difficulty in installing / removing the film, and adhesion problems when using different print feeds extruded at different temperatures. The film is generally not resistant to high surface temperatures, leading to damage to the film itself and subsequently to the print bed surface. Furthermore, inconsistent heating / melting of fine particles / granules during extrusion and the extruder's inability to maintain a consistent temperature are further drawbacks of the reported designs.

[0013] Given the aforementioned shortcomings of existing 3D printer print beds, there remains a growing need to improve their flexibility, usability, and effectiveness for high-quality 3D output in diverse applications. Furthermore, considering the need to maintain specific high temperatures, particularly for plastic-metal composite printing feeds, a heated build chamber capable of maintaining reasonable temperature levels over a predetermined time period is required. The heated build chamber should also help protect the sensitive components of the 3D printer from excessive heat generated during printing without impairing the 3D printing operation. Additionally, to accommodate a wide range of printing feed materials and to ensure smooth printing, the extruder design needs to handle varying temperature conditions and printing speeds required by the application. Summary of the Invention

[0014] The following provides a brief overview of one or more embodiments of this disclosure to provide a basic understanding of these embodiments. This invention is not an exhaustive review of all conceived embodiments, nor is it intended to identify all key or decisive factors of all embodiments, nor is it intended to limit the scope of any or all embodiments.

[0015] Customized, large-scale, general-purpose 3D printing apparatuses using hybrid composite materials can address some or all of the aforementioned problems. Such 3D printing apparatuses may require highly specific part designs to meet finished product requirements. Therefore, various embodiments of this disclosure include specially constructed, large-scale, general-purpose, cost-effective additive manufacturing systems based on 3D printers, capable of printing industrial-scale articles using a variety of hybrid raw materials, including, for example, plastics, ceramics, and polymers, as well as metals and metal-plastic composites. The proposed additive manufacturing systems can combine the features of fused filament manufacturing and fused particle manufacturing while overcoming the drawbacks associated with each technology deployed individually, allowing particle printing (continuous printing without filament spool replacement), thereby expanding the scope, size, quality, and speed of polymer-based additive manufacturing while reducing costs. According to at least some of the various embodiments disclosed herein, six specific blocks—a heated bed, a heated build chamber, a particle feeder system, an extruder, kinematics, and electronics—can be included within the disclosed 3D printer.

[0016] According to at least one of the disclosed embodiments, a complex pellet feeder system forms the backbone for holding and distributing (on demand) raw material for printing purposes. The pellet feeder system may include a cylindrical hopper for receiving pellets, a pneumatic drying mechanism for drying the pellets prior to distribution for printing, and a blower-based system for filling the hopper with dried pellets when a sensor detects a critically low level in the reservoir. According to at least one embodiment, multiple sensors may be installed within the pellet feeder device to detect and report the presence of pellets within the system and ensure proper pellet filling, thereby enabling uninterrupted operation of the 3D printer. According to at least one embodiment, a pneumatic blower mechanism may be included within the cylindrical hopper to ensure proper emptying of the hopper and prevent any unused printing feed from being unintentionally collected and causing blockages within the feed mechanism. The periodic operation of the pneumatic blower mechanism ensures proper emptying of the cylindrical hopper, ensuring smooth flow of pellets within the extrusion system.

[0017] At least one embodiment of this disclosure includes multiple extruders that melt granules to produce a printed physical object. According to at least one embodiment, the extruder may include a secondary granule hopper that holds granules before melting them. Each extruder may have at least one screw. The screw or multiple screws within the extruder may convey individual fine particles / granules from the secondary granule hopper to a plasticizing zone, where the particles may be melted and metered through nozzles designed from a metal alloy. A cooling device may be attached inside the extruder, preventing the screw from overheating. Multiple sensors within the extruder body enable monitoring of temperature, detection of particle presence, and / or reporting of the operational status of the extrusion process.

[0018] Several embodiments of this disclosure propose designs for a heated vacuum stage used as a print bed in a 3D printer. At least one embodiment includes a specially designed aluminum surface serving as a heated / heated vacuum stage, which functions as a print bed, wherein multiple heating elements are embedded within the aluminum surface to maintain a desired temperature at the print bed surface. To maintain the required adhesion of the final product, the heated print bed can be mounted on a frame, and a vacuum distributor can be connected to the heated print bed from below. Convection units with heaters can be mounted to the left and right sides of the print stage to mix and maintain the air in the chamber at a set temperature. In at least one embodiment, the print bed can be mounted below within a convection unit equipped with a vacuum generating mechanism. This convection unit can be directly mounted on the 3D printer frame, concealed by a corresponding convection panel, with vacuum lines extending below the structure. According to at least one embodiment, the unit can be configured such that heat from the convection unit provides a uniform temperature rise within the heated build chamber. In at least one embodiment, systematically etched surface vacuum channels connected to multiple vacuum canisters mounted in the bottom can also be available on the top surface of the heated vacuum stage to ensure a desired suction level on the print bed. According to at least one embodiment, the print bed may be covered with a disposable sheet of semiconductor material that has good adhesion to the object being printed and is held in place by a vacuum mechanism. Multiple stainless steel supports may be attached to the bottom of the print bed to allow it to be placed and secured to the 3D printer frame.

[0019] At least one embodiment of this disclosure includes a durable, impact-resistant, ergonomic, and easily customizable kinematic unit / gantry capable of moving the extruder head at a maximum speed of 2 m / s (e.g., up to 60 kg). The device may include a frame for the kinematic platform, which may include a cubic metal frame with built-in conduits for cables, mounting points for pulleys, and multiple tracks and brackets. The kinematic structure supporting the gantry's movement in the horizontal (XY plane) may include a lightweight rectangular metal gantry housing multiple linear and servo motors, ball screws, and a gantry for mounting the extruder. Vertical (Z plane) movement may be achieved by another set of motors capable of moving the entire gantry along the Z-axis as needed for a printing job. The extruder may be connected to this metal gantry, and its movement is supported by the kinematic device.

[0020] At least one embodiment of this disclosure includes a dynamically enclosed heated build chamber configured to maintain a desired printing environment during the printing process. According to at least one embodiment, the heated build chamber may be constructed between a top kinematic gantry and a bottom heated print bed, with a heat shield on the sides. The chamber can maintain a constant temperature throughout the printing process to ensure proper adhesion of multiple printed layers and greater structural strength of the finished product, or this can also be achieved by using one or more coolers if variable temperatures are required during printing of specific materials and shapes. A lightweight corrugated protective sheet made of rubber or covered with fluoroplastic glass fabric (for the XY plane) and aluminized glass fabric (for the Z plane) can help provide thermal insulation for other components while allowing the kinematically required movement. The corrugated shield can be mounted such that the top of the shield is connected to the kinematic gantry, with the lower portion extending below the heated print bed.

[0021] According to at least one embodiment of this disclosure, the heat shield can be formed of a four-sided corrugated surface, including three vertical sides extending downward from the kinematic gantry to the heating vacuum stage, and a fourth horizontal side forming the top of the heating build chamber at the bottom end of the lightweight extrusion gantry. The corrugated nature of the vertical heat shield allows the expansion / contraction of the heat shield to vertically expand / contract the heating build chamber as the kinematic gantry moves upward / downward along the Z-axis, respectively. The vertical corrugated heat shield can be made of aluminized glass fabric, while the top side can be made of rubber or covered with fluoroplastic glass fabric.

[0022] At least one embodiment of this disclosure may include one or more electronic circuits to control and operate the 3D printing mechanism. For example, multiple satellite boards may be configured to control the pneumatic operation, electrical connections, and sensor information of the entire 3D printer. These satellite boards may be connected to a central board that controls the engine and exchanges data with the satellite boards for optimal printer operation. Inter-board communication may be performed via a CAN interface, with the central board executing all algorithms and making decisions to guide the operation of the satellites.

[0023] According to some embodiments of this disclosure, a thermal insulation housing can be installed beneath the print bed. The thermal insulation housing may include multiple vacuum receiver points for connection to the vacuum tank of the print bed, and mounting points for securing the vacuum stage by bolting them securely to a stainless steel support mounted beneath the print bed. Furthermore, a specially formulated kaolin-wool-based cushion can be inserted into the space between the print bed and the thermal insulation housing to ensure high insulation levels, thereby maintaining the required temperature within the heated build chamber.

[0024] According to some embodiments of this disclosure, multiple convection units and tangential fans can be mounted on either side of the heated vacuum stage, corresponding to the base of the heated build chamber. The tubular convection units heat the air beneath the heated vacuum stage, which can be circulated within the heated build chamber by the mounted tangential fans to maintain an internal temperature of up to 150°C. Active control of the convection fan assembly can help ensure a desired temperature required for the printing process.

[0025] While several embodiments have been disclosed, other embodiments of this disclosure will become apparent to those skilled in the art from the following detailed description, which illustrates and describes illustrative embodiments of the described systems and methods. As will be appreciated, modifications can be made to the various embodiments of this disclosure in a variety of obvious ways, all without departing from the spirit and scope of this disclosure. Attached Figure Description

[0026] A more complete understanding of the disclosed embodiments and their many accompanying advantages will become apparent from the following detailed description, particularly when considered in conjunction with the accompanying drawings, in which:

[0027] Figure 1 A perspective view of a 3D printer according to an embodiment of the present disclosure is shown;

[0028] Figure 2 A perspective view of a 3D printer without a protective panel according to an embodiment of the present disclosure is shown, in which internal components are exposed.

[0029] Figure 3 shows an exploded view of several components of a pellet feeder system according to an embodiment of the present disclosure;

[0030] Figure 4 A perspective view of the particle feeder column of FIG3, mounted on a subframe of a 3D printer according to an embodiment of the present disclosure, is shown.

[0031] Figure 5 A cross-sectional view of an extruder column according to an embodiment of the present disclosure is shown;

[0032] Figure 6 A perspective view of a lightweight gantry according to an embodiment of the present disclosure is shown;

[0033] Figure 7 A detailed view of a lightweight gantry with XY linear motion kinematics according to an embodiment of the present disclosure is shown;

[0034] Figure 8 An exploded view of a heated printing bed and its installation according to an embodiment of the present disclosure is shown;

[0035] Figure 9 A perspective view of the top surface of a heated vacuum stage according to an embodiment of the present disclosure is shown;

[0036] Figure 10 A perspective view of the bottom side of a heated vacuum stage according to an embodiment of the present disclosure is shown;

[0037] Figure 11 A perspective view of a thermal insulation housing according to an embodiment of the present disclosure is shown;

[0038] Figure 12 A perspective view of a heated vacuum stage assembly mounted within the main frame of a 3D printer according to an embodiment of the present disclosure is shown.

[0039] Figure 13 A block diagram depicting the operation of a heated vacuum stage according to an embodiment of the present disclosure is presented;

[0040] Figure 14 A snapshot of the final thermal vacuum chamber with an isolation shroud having XY and Z axes according to an embodiment of the present disclosure is shown.

[0041] Figure 15 A perspective view of a heated building chamber with additional components removed, according to an embodiment of the present disclosure, is shown.

[0042] Figure 16A The corrugated rubber or fluoroplastic-coated plastic insulators forming the sides of the heated building chamber according to embodiments of the present disclosure are shown.

[0043] Figure 16B A corrugated shielding is shown forming the top of a heated building chamber according to an embodiment of the present disclosure;

[0044] Figure 17A A perspective view of a corrugated fluoroplastic insulation structure for XY plane thermal insulation is shown;

[0045] Figure 17B A side view of a corrugated fluoroplastic insulation structure for XY plane isolation is shown, depicting a woven pattern;

[0046] Figure 18 A diagram depicting the temperature retention capability of an XY-planar corrugated fluoroplastic insulator is shown;

[0047] Figure 19 A perspective view of a heated build chamber with additional components removed, according to an embodiment of this disclosure, is shown; and

[0048] Figure 20 A snapshot of a heat shield installed below a heated vacuum stage according to an embodiment of the present disclosure is shown. Detailed Implementation

[0049] Embodiments of this disclosure will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, of the embodiments of this disclosure. A better understanding of this disclosure will be achieved by referring to the definitions, examples, and descriptions provided herein.

[0050] Figure 1 A perspective view of a 3D printer 10 according to an embodiment of the present disclosure is shown. The 3D printer 10 may include one or more removable protective panels 11, 13, 14, and 19 forming all or a removable portion of the housing of the 3D printer 10. Panels 11, 13, 14, and 19 may conceal the internal workings of the 3D printer 10. In some embodiments, one protective panel may be a top panel 13. The top panel 13 may be provided with ventilation vents to exhaust any fumes generated during the 3D printing deposition process. The 3D printer 10 may include one or more tethering points 12. For example, in some embodiments, four identical tethering points 12 may be located on the frame of the 3D printer 10. For example, the tethering points 12 may be used to lift or move the 3D printer 10 during placement. LED lights 15 or other indicators may be located on the outer edge of the frame of the 3D printer 10 and may provide visual indication of the operating status of the 3D printer 10. The printing process and progress monitoring can be controlled via a control panel 17 and a control screen 16 mounted on the 3D printer 10. For example, in the illustrated embodiment, the control panel 17 and control screen 16 are located on the right front panel of the 3D printer 10. Access to the print bed (and the completed printed object) can be provided through a sufficiently large opening 18 provided in the 3D printer 10. For example, in the illustrated embodiment, the opening 18 is located at the front of the 3D printer 10.

[0051] Remove protective panels 11, 13, 14 and 19 ( Figure 1 This reveals the placement of internal components of the 3D printer 10, such as... Figure 2As depicted in the example embodiment. The 3D printer 10 may include a main frame 21 having an additional frame mounting component 22 securely attached to the main frame 21. A lightweight metal gantry 23 may be fixed to the main frame 21 and may house a gantry assembly 24. An extruder assembly 25 may include a plurality of extruders fixed to the gantry, wherein a plurality of servo motors enable the extruder assembly 25 to move in the XY plane as required by the printing job. Additional servo motors 26 may be mounted on the main frame 21 of the 3D printer 10. For example, in the illustrated embodiment, at least four servo motors 26 may be located at each of the four top corners of the main frame 21. As the height of the printed object increases during a printing job, these servo motors 26 can achieve vertical (Z-plane) movement of the extruder assembly 25 by physically moving the lightweight metal gantry 23 vertically along the main frame 21 of the 3D printer 10. A heated build chamber 27 may form part or all of the main print shell of the 3D printer 10. The heated build chamber 27 can be formed by surrounding the gap between the lightweight metal gantry 23 and the bottom of the 3D printer 10 frame 21 with a corrugated rubber-plastic spacer 28. The corrugated rubber spacer 28 allows the heated build chamber 27 to expand and contract as the lightweight metal gantry 23 rises or falls, as controlled by the requirements of the printing job. The heated print bed 29 can be placed inside the heated build chamber 27 and can form all or part of the main worktable for printing jobs performed by the 3D printer 10.

[0052] The 3D printer 10 may include an additional frame mounting assembly 22, which houses auxiliary equipment that provides and / or performs at least some of the functions of the 3D printer 10. Multiple pellet feeder units 210 can serve not only as storage hoppers for holding the print feed in pellet form, but also as tools for drying the pellets using air supplied by a pellet blower 211 before vacuum feeding into the extruder assembly 25. An air pump blower 212 can pneumatically force the dried pellets into the extruder storage to aid in feeding the dried pellets from the pellet feeders 210 into the extruder assembly 25. A cooler unit 213 can help regulate the temperature within the heated build chamber 27 according to the requirements of the print job. One or more cabinets 214 may contain electronic circuitry (e.g., a control board) configured to perform and / or supervise the operation of the 3D printer 10.

[0053] Figure 3a illustrates an example pellet feeder column 30 according to an embodiment of the present disclosure. The pellet feeder column 30 may include a top flange 31 connected to a dry pellet reservoir and serving as an inlet for feeding and temporarily storing dry pellets before extrusion. A central T-shaped section 32 stores newly fed dry pellets while maintaining a tight vacuum within the column via a vacuum inlet 32a connected to a vacuum pump. A transparent secondary pellet reservoir 33 stores freshly fed pellets before they are fed to the extruder. Multiple gaskets and seals 35, 36, 37, and 38 ensure a tight vacuum within the column, protecting the dry pellets from environmental degradation and providing an efficient handling and dispensing mechanism for the dry pellets. A U-shaped flange 34 may be disposed at the bottom of the secondary pellet reservoir 33. An optical sensor 34a, connected via a cable 34b to the main electronics board and mounted in the U-shaped flange 34, detects the presence and flow of pellets from the secondary pellet reservoir during extrusion. Sensor 34a can detect blockages that occur during printing and / or the need for replenishing particle feed. Sensor 34a can report the detected blockages and / or replenishment needs to the main control board, which can trigger subsequent actions.

[0054] Figure 3b shows a modified version of the transparent secondary particle storage tank 33 according to an embodiment of the present disclosure. A metal tube 39 connected to a pneumatic pump can be installed inside the transparent secondary particle storage tank 33. Static charge buildup during the printing process can cause printed feed particles to adhere to the walls of the transparent secondary particle storage tank 33, resulting in the particle sensor 34a recording erroneous readings. By periodically blowing pressurized air through the metal tube 39, any remaining printed feed particles can be blown into the printing process, allowing the sensor 34a to report the actual state of the particles.

[0055] Figure 4 A perspective view is shown of two particle feeder columns 30 (e.g., as shown in Figure 3a) mounted on a dedicated subframe 41, which is securely mounted in an additional frame mounting assembly 22 (e.g., as shown in Figure 3a). Figure 2 (As shown). A vortex blower 42 can be installed in the sub-frame 41 and can fill the pellet feed column 30 when needed. A pneumatic distribution system 43 can be installed in the sub-frame 41 (e.g., at the bottom as shown) and can be connected to the outlet 38 of the pellet feed column 30. Particles from the pellet feed column 30 can fall into the pneumatic distribution system 43, and under the force of compressed air fed through one end 44, they can be conveyed through the other end 45 of the pneumatic distribution system 43 to the extruder assembly.

[0056] Extruder assembly 25 ( Figure 2 (This may include multiple individual extruders 50. According to some embodiments, a cross-sectional view of one of the extruders 50 is shown in...) Figure 5 As shown in the diagram. The extruder 50 may include an extruder frame 51, which serves as a support for mounting other extruder 50 equipment, and also includes the necessary mechanical mechanisms to assist in the extension and retraction of the extruder 50. (Source: [Original Source Name]) Figure 4 The pellets in the pellet feeder system can be fed through pellet feed pipe 53 into a local pellet storage tank 52 for temporary storage during the extrusion process. A pellet detection sensor 54 can also be attached to the pellet feed pipe 53 to detect the presence of pellets and their flow into the extruder. The pellets from the local pellet storage tank 52 can then be fed through a specially designed screw 56 to a pellet trap cone 55, enabling continuous pellet distribution for uniform extrusion and preventing clogging. The speed and consistency of the extruded filament can be controlled by the rotational speed of the screw 56, which can be controlled by a stepper motor 57, the speed of which can be adjusted, for example, based on the type of printed pellets and / or the size of the final object. Multiple independently adjustable heater units 58 can heat the screw to the desired temperature, causing the pellets conveyed downwards by the rotational motion of the screw 56 to melt into a liquid before being extruded from the nozzle 59. A camera 510 can also be mounted to visually monitor the extrusion process and report any blockages within the extruder 50. If the temperature of screw 56 is detected to be higher than the expected value or threshold (for a certain type of print feed material), cooler 511 can be activated to reduce the extrusion chamber temperature to a level that ensures the viscosity of the molten print feed is acceptable for high-quality extrusion. Multiple cooling tubes 512 can also be installed directly below nozzle 59 to accelerate the cooling process of the extruded layers, thereby ensuring the final product has the required structural rigidity. Tables 1-3 show the extrusion performance of the designed extruder 50 for different types of print feeds. The average weight, standard deviation, estimated print speed (in g / hr), and percentage deviation of the extruded samples were recorded by independently adjusting the temperature of each individual heater unit 58 and extruding the print feed at different extrusion speeds (v).

[0057] 3D printing jobs typically require extruding components 25 ( Figure 2 The movement of the extrusion assembly 25 in both the horizontal (XY plane) and vertical (Z plane) directions. Figure 2 It can be installed on a lightweight metal gantry, an example of which is shown in Figure 6 As shown in detail, the gantry may include a metal frame 61 with a Y-axis magnetic rail 62 mounted thereon to ensure smooth movement of the extruder assembly 25 along the Y-axis. Figure 7A complete view of an example gantry 70 equipped with X-axis and Y-axis motion mechanisms is shown. To achieve movement along the X-axis, an X-plane linear module 71 can be mounted on each of the two sides of the lightweight metal gantry 70 corresponding to the X-axis. In some embodiments, the X-plane linear module 71 may include a linear motor or servo motor 72 attached to one end of a linear guide 73, with a Y-axis mounting plate 74 mounted at the opposite end. One or more X-plane linear modules 71 (e.g., two, as shown) can be mounted on opposite sides of the lightweight gantry 70 through multiple mounting points 74, and can be configured according to... Figure 7 The coordinates shown are along the X-axis. Each end of the Y-axis magnetic track 62 can be bolted or otherwise directly fixed to each of the respective Y-axis mounting plates 74 of the two identical X-plane linear modules. Once started, each of the two X-plane servo motors 72 can synchronize its movement to move the Y-axis magnetic track 62 along the guide rail 73 across the X-axis at a constant speed, as indicated by the arrow. The vertical (Z-plane) movement of the lightweight gantry 70 can be achieved by moving the Y-axis magnetic track 62 across the main frame 21 ( Figure 2 One or more linear modules (e.g., four, as shown) are vertically mounted on the four vertical arms of the gantry. The lightweight gantry 70 can be suspended from the Z-plane linear modules via mounting points 76 attached to each corner of the lightweight gantry 70.

[0058] Table 1. Extruder performance for polypropylene (PP) printing feed, with four separate heater units 58 operating at temperatures of 260°C, 250°C, 250°C and 240°C respectively.

[0059]

[0060] Table 2. Extruder performance for polyphenylene sulfide (PPS) printing feed, with four separate heater units 58 operating at temperatures of 300°C, 310°C, 300°C and 290°C respectively.

[0061]

[0062] Table 3. Extruder performance for acrylonitrile butadiene styrene (ABS) printing feed, wherein four separate heater units 58 operate at temperatures of 240°C, 250°C, 240°C and 190°C respectively.

[0063]

[0064] A heated print bed, or heated vacuum stage, can be shaped into a flat rectangular surface and can be made of aluminum or glass. The heated bed can be fixed to the build platform of a 3D printer and used as a worktable for the actual 3D printing process. Figure 8A complete print bed assembly according to an embodiment of the present disclosure is shown. The apparatus may include an aluminothermic print bed 81 with dedicated channels 82 milled on its surface to form a grid of different sizes, thereby generating and maintaining a vacuum under the work surface at the start of printing. A grid of special surface heating elements directly embedded in an aluminum sheet of the thermal vacuum stage enables heating of the stage surface. The underside of the thermal vacuum stage 81 may have multiple mounted stage supports 83 and multiple vacuum tanks 84 to maintain a vacuum on the stage surface. The thermal print bed 81 may be securely mounted on a convection frame 85, which includes multiple vacuum sensors 86 for direct engagement with corresponding vacuum tanks 84 of the thermal vacuum stage 81. Multiple thermal protection plates 87 at the bottom of the convection frame 85 help protect against heat dissipation outside the convection assembly. The convection frame 85 may be securely bolted or otherwise fixed to the bottom panel 88 of the main 3D printing frame 22. Figure 2 Decorative cover panels 89, 90, and 91 can be provided to conceal gaps between components, thus providing a tight-fitting appearance. Once the desired temperature is set, the heating element inside the thermal vacuum stage 81 can be activated, and the surface of the thermal vacuum stage 81 can be heated to the desired surface temperature.

[0065] Figure 9-10 A perspective view showing the top and bottom sides of the heated vacuum stage 11 is shown. The top surface of the heated vacuum stage 121 may include one or more vacuum channels 82 etched through a surface area of ​​the heated vacuum stage 11. One or more heating elements may be mounted on the stage surface by pouring them onto molten aluminum during stage creation. These channels can be used to generate the necessary suction to maintain the desired adhesion level between the 3D printed object and the heated vacuum stage 11. One or more vacuum canisters 84 may be mounted on the bottom side 124 of the heated vacuum stage 11. A vacuum supply line 123 extending between the vacuum canister 31 and the vacuum generator can provide the necessary vacuum for proper adhesion. The weight of the entire heated vacuum stage 11 may be supported by multiple supports 83, which may be made of stainless steel or other suitable materials and may be designed to be bolted in place, for example, within an insulated housing 112.

[0066] Figure 11A perspective view of a heat-insulating housing 112 securely mounted within the internal frame 113 of a 3D printer is shown. The heat-insulating housing 112 may include a plurality (e.g., four) of mounting plates 141 (identical and equally spaced in this example) welded along the width of the heat-insulating housing 112. A plurality of bolt points 142 may be provided on each mounting plate 141, which can serve as receivers for the same number of compliant stainless steel supports 83 mounted on the underside 124 of the heated vacuum stage 11. Cavities 143 and 144 (identical in this example) on either side of the heat-insulating housing 112 may hold mounted convection devices to generate and maintain a desired level of heating within the heated chamber. Figure 12 The image provides a perspective view of the entire heated vacuum stage assembly mounted within the main frame 113 of the 3D printer. The heated vacuum stage 11 can be bolted to the heat insulation housing 112 via multiple stainless steel support members 83, as shown below. Figure 12 As shown.

[0067] exist Figure 13 The block diagram depicts the function of the heated vacuum stage 11. The operator can set the desired surface temperature through one of multiple 3D printer user interfaces 161. The 3D printer's main control circuitry 162 can activate and command a local controller 163, which in turn activates multiple embedded heating elements 164 of the heated vacuum stage 11, thereby gradually increasing the surface temperature of the heated vacuum stage 11. Simultaneously, depending on the type of print feed used for a specific print job, the local controller 163 can also activate a vortex blower 165, which pumps air through a vacuum receiver 166, thereby initiating an adhesion process on the surface of the heated vacuum stage 11. Once the temperature rises to the desired value, as reported by the surface temperature sensor 167, heating can be stopped, and the process can be maintained and regulated by the local controller 163.

[0068] The heated build chamber can contain all the different functional components of the 3D printer 10 described above. The heated build chamber ensures a constant temperature as the printing process continues. Regulating the ambient temperature ensures proper adhesion of multiple printed layers while reducing the brittleness of the manufactured structure. The heated build chamber may include a cavity 91 formed between the lightweight gantry 70 and the heated print bed 81, such as... Figure 14 As shown. A corrugated shield 92 can be installed, which in some embodiments may be made of aluminized glass fabric, to isolate one or more sides of the cavity (e.g., as shown). Figure 14The three sides of the cavity shown). The top of the corrugated insulating sheet can be attached to the lightweight gantry 70 so that the corrugated sheet folds / unfolds as the gantry moves along the Z-axis, while maintaining the integrity of the heated build chamber. The top surface of chamber 93 can be insulated, for example using specially designed rubber or fluoroplastic-coated glass fabric, allowing movement of the extrusion assembly in the X and Y planes. When the extruder assembly 25 ( Figure 2 When moving along the X-plane, the entire Y-plane corrugated channel 94 can move along the X-plane by expanding / contracting the corrugations 95 as needed. The Y-axis movement of the extruder assembly can be achieved by expanding / contracting the corrugated structure attached to the Y-plane corrugated channel 94. To monitor and control the temperature inside the heated build chamber 91, a series of convection devices can be mounted on the convection device frame 85. Figure 8 It is located on top and can be concealed by covers 89 and 90. The convection unit can operate by heating and circulating the air within the construction chamber 91.

[0069] Figure 15 A detailed view of the heated build chamber 91 without other 3D printer components is shown. The heated build chamber 91 can be created with the kinematic gantry 70 on top. Specially formulated corrugated rubber or fluoroplastic-coated plastic spacers 92 can form three sides of the heated build chamber 91, with the top and bottom ends of the corrugated rubber plastic spacers 92 securely attached to the bottom ends of the kinematic gantry 70 and the main frame 21, respectively.

[0070] Figures 16A-16B It shows the formation Figure 15 Detailed view of the heat insulation shroud surrounding the heated building chamber 91. Figure 16A Three sides of the corrugated rubber or fluoroplastic-coated isolator 92 that can form the heated build chamber 15 are shown. The top side 231 and bottom side 232 of the corrugated rubber isolator 92 can be securely attached to the lower end of the kinematic gantry 70 and the bottom end of the main frame 21, respectively. During printing, any vertical (Z-plane) movement of the kinematic gantry 70 may cause the corrugated rubber or fluoroplastic-coated isolator 92 to contract or expand along the engraved corrugations while maintaining the isolator level without restricting the movement of the kinematic gantry 70. The top surface of the heated build chamber 91 can be covered by a specially designed lightweight rectangular metal frame 235 having two different and independently movable corrugated structures 94 and 95, mounted within the lightweight rectangular metal frame 235, such as... Figure 16B As shown. A lightweight metal frame 235 can be mounted below the kinematic gantry 70, to which the top 231 of the corrugated insulator 92 is attached. The corrugated insulator 92 can be made of rubber or fluoroplastic material (e.g., PTFE) and has a two-layer structure woven together, such that multiple corrugated units 171 are formed throughout the corrugated insulator 92 enclosure, as... Figure 17B As shown. The pattern is in Figure 17APerspective and Figure 17B As shown in the side view. The narrow corrugated heat shield channel 94 provides a sufficiently wide opening for the extrusion assembly to extend into the heated build chamber 91, wherein the narrow corrugated heat shield channel 94 provides Y-axis movement of the extrusion assembly. X-axis movement of the extrusion assembly can be provided by the wider corrugated heat shield channel 95. The combination of the two heat shield channels 94 and 95 ensures unobstructed movement of the extrusion assembly while limiting heat dissipation through the top of the heated build chamber 91.

[0071] Figure 18 The temperature retention performance of different components of the disclosed apparatus is shown. The figure illustrates the temperature at different locations within the heated build chamber 91 with the corrugated isolator 93 in place. Temperature readings at four different locations are available for the entire test duration of 137 minutes: TC1 Inside the isolation room, TC2 Outside the room and above the corrugated isolator 93, TC3 and TC4 Within corrugated unit 171. From Figure 18 As can be clearly seen, the newly designed corrugated isolator 93 acts as an effective heat shield by maintaining the temperature inside the heated build chamber 91. The colors in the diagram are as follows: blue – temperature of the heated bed, black – temperature of the heated chamber, green – temperature inside the printer above the corrugated shield, red – temperature near the Y-axis magnetic encoder, purple – temperature near the X-axis track end switch, yellow – temperature inside the printer behind the screen, and turquoise – temperature inside the electrical panel. The test lasted 8 hours, with the chamber setpoint set at 150°C and reached within 20 minutes, and the bed setpoint set at 220°C and reached within 1.5 hours. Kinematics was initiated at 660 mm / s after 85 minutes of temperature stabilization during the test. During the test, the temperature inside the printer stabilized at the following values: 105°C above the corrugations, 50-51°C at the magnetic encoder and X-axis end, 37°C inside the electrical panel, and 38°C behind the printer screen. Operation of the kinematic gantry 70 was observed to be stable for over 6 hours under X-axis loads of 32% slave, 45% master, and 8% Y-axis. According to the test results, the kinematic gantry 70, the heated build chamber 27, and the heated print bed 29 operated stably for more than 6 hours at preset chamber temperatures of 150°C and 220°C.

[0072] To generate and maintain the required temperature level within the heated construction chamber, one or more convection fans 241, supported by tangential or other types of fans, can be mounted on either side of the heated vacuum stage 81, such as... Figure 19 As shown. The convection unit may include one or more heating elements (e.g., multiple 9 kW tubular heating elements), whose heat output can be circulated within the heating build chamber by a fan mounted on either side of the heating vacuum stage 81.

[0073] Figure 20 A snapshot shows an insulation structure that can be installed beneath the heated vacuum stage 81. A lightweight frame 251 can form the base of the heated building chamber and may contain the heated vacuum stage 81 mounted therein. One or more robust pads 252 filled with kaolin or another suitable material can be installed beneath the heated vacuum stage and / or in the empty space within the lightweight frame 51. The robust pads 252 can form an insulating layer to protect against heat loss from beneath the heated vacuum stage 81.

[0074] It should be understood that this disclosure is not limited to the embodiments described above, but includes any and all embodiments within the scope of the appended claims. In view of the foregoing teachings, many modifications and variations of this disclosure are possible. Therefore, it should be understood that the details disclosed may be implemented in ways different from those specifically described herein within the scope of the appended claims.

[0075] The disclosed embodiments have been designed for (1) rapid prototyping in any discipline, including materials science, aerodynamics, fluid dynamics, engineering research, and rapid iteration of products requiring testing; (2) modeling from digital models to physical representations in architecture, engineering, education, art, and design; (3) tooling and overall production in the automotive, aerospace and space exploration, shipping and maritime, defense, energy, oil and gas, mining, medical devices, healthcare, footwear, consumer goods, architecture (replacement elements for building elements and restorations), film and theater industries (ornaments and prosthetics), and art and design, including generative design, furniture design, small and large artworks, fashion items, footwear, head and jewelry or decorative elements, especially items with complex geometries, in any industrial sector. It should be understood that the disclosed embodiments may have additional or different uses beyond or in lieu of those listed herein.

[0076] The disclosed embodiments are compatible with all known forms of investment casting, small-batch manufacturing, and field manufacturing for use in hospitals, dental clinics, construction sites, on transport ships or submarines, harbor warehouses, oil platforms and offshore structures, oil and gas fields, mining sites, remote and extreme environments including Arctic and Antarctic stations and space exploration, military environments (e.g., specialized equipment, drones, and replacement parts manufactured using faulty units), etc.

[0077] Thanks to the innovative integration of the active chamber with multiple atmosphere-controlled systems, and the advanced motion system optimized for high-speed, large-scale production with a maximum resolution of 50 μm, the embodiments described herein offer the advantage of greater isotropy in terms of the size of the printed object, while maintaining the highest degree of isotropy within its category. Compared to filament-based systems, the ability to print from thermoplastic and composite particles, granules, or fine particles enables a significantly wider range of thermoplastic materials, even including plastics that cannot be used in filament form (e.g., brittle thermoplastics) and compositions with high internal viscosity or thixotropic properties, whose flow characteristics are, for example, similar to Newtonian fluids.

[0078] The embodiments described herein may include a fully circular apparatus that can include the preparation of printing materials and post-production by seamlessly integrating pre-production and post-production equipment into a single ecosystem that minimizes additional purchase and maintenance costs and provides users with a process for pre-testing and fine-tuning. The designs and setups of the embodiments disclosed herein can allow for the shredding and reuse of printing objects of any size, unfinished spools, spool holders, and end caps, thereby eliminating intermediate steps in filament production and reducing material waste and contamination.

Claims

1. A 3D printer, comprising: frame; At least one panel, which is removably attached to the frame and defines a printed cover; A heated build chamber is located within the printed casing; A heated printing bed that defines the bottom of the heated build chamber; An extruder assembly configured to move within the heated build chamber; as well as At least one pellet feeder is configured to feed pellets of working material into the extruder assembly.

2. The 3D printer according to claim 1 further includes at least one tethering point disposed on the outer area of ​​the 3D printer.

3. The 3D printer according to claim 1 further includes at least one display element, the at least one display element being disposed on an external area of ​​the 3D printer and configured to display operation information of the 3D printer.

4. The 3D printer of claim 1, wherein, The heated building chamber is defined by a movable gantry coupled to the frame and at least one corrugated partition, the corrugated partition being coupled to the gantry and configured to expand and contract as the gantry moves vertically.

5. The 3D printer of claim 4, wherein, The at least one corrugated insulating sheet comprises aluminized glass fabric.

6. The 3D printer of claim 1, wherein, The top of the heated construction chamber includes a rubber-glass fabric insulator.

7. The 3D printer of claim 1, wherein, The heated printing bed includes: Top side, which includes a surface in which at least one vacuum channel is formed; At least one heating element is coupled to the surface and / or integral with the surface; The bottom side, which is opposite to the top side; and At least one vacuum tank is attached to the bottom side and configured to create a vacuum within the at least one vacuum channel.

8. The 3D printer of claim 7, wherein, The heated printing bed also includes at least one vacuum generator and at least one vacuum supply line, the at least one vacuum supply line being connected to the at least one vacuum generator via the at least one vacuum tank.

9. The 3D printer of claim 7, wherein, The heated printing bed also includes a heat-insulating housing configured to accommodate the surface.

10. The 3D printer of claim 7, wherein, The heating vacuum stage also includes at least one support member, which connects the bottom side to the heat insulation shell.

11. A method comprising: A heated build chamber and print bed for a 3D printer, the 3D printer including a frame, at least one panel, an extruder assembly and at least one pellet feeder, the at least one panel being removably coupled to the frame and defining a print shell, the heated build chamber being located within the print shell, and the heated print bed defining the bottom of the heated build chamber; as well as The printing operation using the 3D printer includes moving the extruder assembly within the heated build chamber and feeding particles of working material into the extruder assembly via the at least one particle feeder.

12. The method of claim 11, further comprising displaying operation information of the 3D printer by means of at least one display element disposed on an external area of ​​the 3D printer.

13. The method of claim 11, wherein, The heated building chamber is defined by a movable gantry connected to the frame and at least one corrugated partition connected to the gantry. The method further includes vertically moving the gantry and causing the at least one corrugated partition to expand and contract as the gantry moves vertically.

14. The method of claim 11, further comprising creating a vacuum in at least one vacuum channel within the top surface of the heated printing bed by means of at least one vacuum canister coupled to the bottom side of the heated printing bed.

15. The method of claim 14, wherein, The heated printing bed also includes at least one vacuum generator and at least one vacuum supply line, the at least one vacuum supply line being connected to the at least one vacuum generator via the at least one vacuum tank.

16. A 3D printer, comprising: frame; At least one panel, which is removably attached to the frame and defines a printed cover; A heated build chamber is located within the printed casing, and multiple sides of the heated build chamber are defined by multiple corrugated insulating sheets; as well as A heated printing bed that defines the bottom of the heated build chamber.

17. The 3D printer of claim 16, further comprising: An extruder assembly configured to move within the heated build chamber; as well as At least one pellet feeder is configured to feed pellets of working material into the extruder assembly.

18. The 3D printer of claim 16, further comprising at least one convection device configured to heat the heated build chamber.

19. The 3D printer of claim 16 further includes an isolator disposed below the heated printing bed.

20. The 3D printer of claim 16, wherein, The insulator includes one or more pillows.

21. The 3D printer of claim 20, wherein, The one or more pillows are filled with kaolin cotton.

22. The 3D printer of claim 17, further comprising at least one servo motor and / or at least one linear motor configured to move the extruder assembly.

23. The 3D printer of claim 17, wherein, The at least one pellet feeder includes a pellet reservoir, a controlled environment chamber connected to the pellet reservoir, and an outlet connected from the controlled environment chamber to the extruder assembly.

24. The 3D printer of claim 17, wherein, The at least one particle feeder includes at least one sensor configured to detect the presence or absence of particles inside the at least one particle feeder.

25. The 3D printer of claim 17, wherein, The at least one pellet feeder includes a pneumatic distribution system configured to distribute the pellets to the extruder assembly.

26. The 3D printer of claim 17, wherein, The at least one particle feeder includes a vortex blower configured to supply the particles into the interior of the at least one particle feeder.

27. The 3D printer according to claim 17, wherein, The at least one particle feeder also includes a pneumatic device configured to remove any remaining particles from the particle reservoir.

28. The 3D printer according to claim 17, wherein, The extruder assembly includes multiple individual extruders.

29. The 3D printer according to claim 17, wherein, The extruder assembly includes a nozzle and a screw, the screw being configured to continuously feed the particles from the at least one particle feeder into the nozzle for extrusion.

30. The 3D printer according to claim 29, wherein, The extruder assembly includes a heater unit configured to heat the cylindrical portion of the extruder, thereby melting the particles as they are fed from the at least one particle feeder into the nozzle.

31. The 3D printer according to claim 29, wherein, The extruder assembly includes a cooling unit to forcibly reduce the temperature of the cylindrical portion of the extruder.

32. The 3D printer according to claim 17, wherein, The extruder assembly includes a gantry comprising at least one x-axis kinematic mechanism and at least one y-axis kinematic mechanism configured to move the extruder assembly.

33. A method comprising: A heated build chamber and print bed for a 3D printer, the 3D printer including a frame, at least one panel removably coupled to the frame and defining a print shell, the heated build chamber being located within the print shell, multiple sides of the heated build chamber being defined by multiple corrugated partitions, and the heated print bed defining the bottom of the heated build chamber; as well as The 3D printer is used for printing.

34. The method according to claim 33, wherein, The printing operation includes moving an extruder assembly within the heated build chamber and feeding particles of working material into the extruder assembly via at least one particle feeder.

35. The method of claim 34, further comprising detecting the presence or absence of the particles inside the at least one particle feeder by means of at least one sensor.

36. The method of claim 34, further comprising supplying the particles into the interior of the at least one particle feeder by means of a vortex blower.

37. The method of claim 34, further comprising removing any remaining particles from the particle storage container by means of a pneumatic device.

38. The method of claim 34, further comprising continuously feeding the particles from the at least one particle feeder into the nozzle via a nozzle and a screw for extrusion.

39. The method of claim 38, further comprising heating the cylindrical portion of the extruder by a heater unit to melt the particles as they are fed from the at least one particle feeder into the nozzle.

40. The method of claim 39, further comprising forcibly reducing the temperature of the cylindrical portion of the extruder by means of a cooling unit.

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