Consumable assembly of 3D printer and 3D printer

Abstract

The utility model relates to a consumable assembly of a 3D printer and the 3D printer, and the consumable assembly (12) of the 3D printer (10) comprises a bobbin (200) for bearing a winding filament (202). The spool is configured to be mounted into a spool cabinet (52) to maintain the filaments in a controlled environment. A filament key fob (204) carrying a spool chip (306) programmed with identification data for the consumable assembly is tethered to the spool. The filament key fob is configured to be received in a base (68) of the 3D printer outside of a controlled environment of a chamber (54) of the spool cabinet while remaining tethered to a spool mounted in the chamber of the spool cabinet.

Description

Technical Field

[0001] This disclosure relates to an additive manufacturing system for 3D printing parts using material extrusion technology. Specifically, this disclosure relates to a filament assembly for a 3D printer and a 3D printer having a spool of consumable filament having an electronic identification device (sometimes referred to as a spool chip) carried in a filament keychain attached to the spool and configured to communicate with the printer. All references disclosed herein are incorporated herein by reference. Background Technology

[0002] Additive manufacturing, also known as 3D printing, is the process of building three-dimensional (3D) parts by adding material to form 3D parts rather than subtracting material as in traditional machining. Using one or more additive manufacturing techniques, three-dimensional solid parts of almost any shape can be printed from a digital model of a part using an additive manufacturing system (often called a 3D printer). A typical additive manufacturing workflow involves slicing a 3D computer model into thin cross-sections that define a series of layers, converting the results into two-dimensional positional data, and transmitting the data to a 3D printer, which then manufactures the 3D structure in an additive building manner. Additive manufacturing involves many different manufacturing methods, including material extrusion, inkjet printing, powder bed fusion, binder jetting, direct energy deposition, electron imaging, and reduction photopolymerization (including digital photopolymerization and stereolithography processes).

[0003] In typical extrusion-based additive manufacturing systems (e.g., the fused deposition modeling system developed by Stratasys, Inc., Eden Prairie, MN), 3D parts can be printed from a digital representation of a part by extruding a viscous, flowable or filled thermoplastic material from a printhead along a toolpath at a controlled extrusion rate. The extruded material stream is deposited onto a substrate in the form of a series of paths, where it fuses with the previously deposited material and solidifies as the temperature drops. The printhead includes a liquefier that receives a supply of thermoplastic material in the form of a flexible filament, and a nozzle tip for distributing the molten material. A filament drive mechanism engages the filament with, for example, drive wheels and bearing surfaces or a pair of gears, and feeds the filament into the liquefier, where it is heated to a molten pool. The unmelted portion of the filament essentially fills the diameter of the liquefier tube, providing a plug-flow pumping action to extrude the molten filament material from the tip downstream of the liquefier to print the part, thus forming a continuous flow of resin material or a toolpath. The extrusion rate is not limited, but depends only on the feed rate of the filament into the liquefier, and the filament advances at the calculated feed rate to achieve the target extrusion rate, such as the rate disclosed in U.S. Patent No. 6,547,995 in Comb.

[0004] In addition to depositing thermoplastic resin in fused deposition modeling, the filament supply can also comprise chopped particles or continuous fibers in the form of filament material. This material can be deposited together with or on top of the deposited thermoplastic resin layer, or deposited as a composite filament consisting of continuous fibers in a core, partially coated by a thermoplastic resin shell. The continuous fibers can also be deposited uncoated on top of or together with the molten resin. The feeding method for this filament material is similar to that of resin-only filament materials, using a similar filament drive mechanism.

[0005] In systems where material is typically deposited in planar layers, after each layer is formed, the printhead's position relative to the substrate increases along an axis (perpendicular to the build plane), and this process is repeated to form a printed part resembling a digital representation. When manufacturing printed parts by depositing layers of part material, support layers or structures are typically built beneath overhangs or within the chambers of the printed part being built; these portions are not supported by the part material itself. The support structures can be built using the same deposition techniques used to deposit the part material. The host generates additional geometry as a support structure for the overhangs or free-space portions of the printed part being formed. Support material is then deposited during the printing process according to the generated geometry. The support material adheres to the part material during manufacturing and can be removed from the finished printed part after the printing process is complete.

[0006] Multi-axis additive manufacturing systems can be used to print 3D parts using fused deposition modeling (FDM) technology. A multi-axis system may include a robotic arm capable of moving in multiple degrees of freedom. The system may also include a build platform capable of moving in two or more degrees of freedom, independent of the robotic arm's movement, to position the 3D part being built, counteracting the gravitational effects based on the part's geometry. An extruder may be mounted at the end of the robotic arm and configured to extrude material at multiple flow rates, where the movement of the robotic arm and build platform is synchronized with the flow rate of the extruded material to build the 3D part. Multiple axes of motion can utilize complex toolpaths to print 3D parts, including a single continuous 3D toolpath for the entire part, or multiple 3D toolpaths configured to build individual parts. Using 3D toolpaths can reduce problems associated with traditional planar toolpath 3D printing, such as staggered layers, seams, support requirements, etc. Instead of printing individual layers of a 3D part on a single build plane, the geometry of the part's features can be used to determine the printing orientation.

[0007] Regardless of the printing system architecture used, fused deposition modeling (FDM) printing operations rely on extruding build material from the printhead at a predictable and target extrusion rate, which in turn depends on a reliable method for delivering consumable feedstock to the printhead. In the case of moisture-sensitive filament materials, the filaments are preferably supplied to the printhead in a dry state (e.g., less than 300 ppm of water by weight) to prevent moisture from negatively impacting the extrusion process. Therefore, moisture-proof layers and / or drying systems can be incorporated into the filaments during transport, storage, and use within the printer, and desiccant materials can be included in the consumable components to assist in drying the filaments and keeping them dry during printer storage, transport, and use. There is currently a need to improve the methods and apparatus for filament feedstock delivery in 3D printing systems. Utility Model Content

[0008] According to one aspect of this disclosure, a consumable assembly for a 3D printer is provided, the consumable assembly comprising:

[0009] A spool carrying a wound filament is configured to be mounted in a spool cabinet, which is configured to hold the spool in a controlled environment and supply the filament to the print head of the 3D printer via a filament path;

[0010] A filament keychain, comprising a spool chip retained within a spool chip housing; and

[0011] A tether, separate from the filament path, connects the filament keychain to the spool and is configured to allow the filament keychain to reach the base of the 3D printer located outside the spool cabinet when the spool is installed in the spool cabinet and the tether remains connected to the spool and the filament keychain.

[0012] In one embodiment, the consumable assembly further includes a filament guide for attaching to the filament keychain during transport and storage.

[0013] In one embodiment, the spool chip housing is configured to be detachably attached to the spool for transport and storage.

[0014] In one embodiment, the spool chip includes an identification device for the consumable component.

[0015] In one embodiment, the spool chip is configured to be received in the base of the 3D printer to position the identification device near the corresponding spool chip interface of the 3D printer.

[0016] In one embodiment, the tether connects the spool chip housing to the spool shaft.

[0017] In one embodiment, the filament keychain further serves as a handle configured to be detachably attached to the spool, allowing the spool to be carried by the filament keychain for installation into the spool cabinet of the 3D printer.

[0018] In one embodiment, the spool chip housing is configured to be detachably attached to the edge of the spaced-apart wall of the spool.

[0019] According to another aspect of this disclosure, a 3D printer is provided, the 3D printer comprising:

[0020] A printhead configured to receive filament material;

[0021] A spool cabinet with a chamber, the chamber being configured to have filament spools positioned within the chamber and to provide a controlled environment for the filaments on the spools; and

[0022] A base located outside the chamber of the spool cabinet and configured to receive a spool chip housing for the filament spool, thereby keeping the spool chip outside the controlled environment of the chamber.

[0023] In one embodiment, the spool cabinet includes a door that, when in the closed position, covers both the chamber and the base.

[0024] In one embodiment, the spool chip housing is connected to the filament spool by a tether, wherein the spool cabinet includes a door covering the chamber, the door including a gasket sealing to the frame of the spool cabinet, and wherein a portion of the tether extends between the gasket and the frame when the filament spool is located inside the spool cabinet and the spool chip housing is located in the base.

[0025] In one embodiment, the base includes a notch positioned to allow the tether to be guided out of the spool chip housing when the spool chip housing is located in the base.

[0026] In one embodiment, the base includes a spool chip interface located within the base, the spool chip interface being configured to read data from the spool chip, write data to the spool chip, or otherwise interact with the spool chip.

[0027] In one embodiment, the spool chip and the spool chip housing include a filament spool hanger, and the base is configured to receive the filament spool hanger.

[0028] In one embodiment, the filament spool hanger includes a detachable handle to the filament spool, and wherein the base is configured to receive the detachable handle to the filament spool.

[0029] One aspect of this disclosure includes a filament assembly for a 3D printer. The filament assembly includes a spool carrying a wound filament, wherein the spool is configured to be mounted in a chamber of a spool cabinet to hold the spool in a controlled environment, such as a heated or humidified environment. A filament keychain carrying a spool chip programmed with identification data for the filament assembly is attached to the spool. The filament keychain is configured to be received in a base of the 3D printer located outside the chamber and its controlled environment, while remaining attached to the spool mounted in the chamber of the spool cabinet. The filament keychain of the filament assembly carries the spool chip (which contains identification data for the filament assembly) and is attached to the spool chip. The spool chip is configured to be received in a base of the 3D printer located outside the chamber and to communicate with the 3D printer from within the base. A tether of the filament assembly connects the filament keychain to the spool and continues to connect the filament keychain to the spool when the filament keychain is received in the base outside the chamber of the spool cabinet. In another aspect of some embodiments, the tether is connected to the shaft of the spool.

[0030] In another aspect of this disclosure, the spool chip includes an E-PROM chip, an RFID tag, or other electronic identification device. In yet another aspect, the filament keychain is configured to be received in the base of the 3D printer to position the identification device near the corresponding spool chip interface of the 3D printer.

[0031] In another aspect of this disclosure, the filament keychain is held within a housing configured to attach to and detach from the spool. In yet another aspect, the housing is configured to function as a handle for carrying the spool when attached, and to be received in the 3D printer's base when detached from the spool. The handle allows the operator to carry the filament assembly to install and remove the spool within the 3D printer's spool cabinet while remaining outside the heated environment of the spool cabinet to keep the spool cool to the touch when installing it.

[0032] On the other hand, the handle formed from the filament keychain housing is configured to be detachably attached to the edges of two spaced-apart spool walls. The handle may include first and second snap-fit ​​channels configured to snap-fit ​​onto the edges of the spaced-apart spool walls. The handle may also include a latch release mechanism configured to be actuated to release the handle from the edges of the spaced-apart spool walls. On the other hand, the latch release mechanism of the handle is also configured to function as a release mechanism for securing the handle in the base and releasing the handle from the base.

[0033] Another aspect of this disclosure includes a 3D printer configured to use a filament assembly. The filament assembly includes a spool carrying a wound filament, wherein the spool is configured to be mounted in a spool cabinet to hold the spool in a controlled environment, such as a heated or humidity-controlled environment. A spool chip of the filament assembly contains identification data of the filament assembly and can be tethered to the spool. The spool chip is configured to be received in a base of the 3D printer located outside the spool cabinet and to communicate with the 3D printer while in the base. A tether of the filament assembly attaches a housing of the spool chip to the spool and continues to attach the spool chip housing to the spool while the spool chip is received in the base outside the spool cabinet.

[0034] In another aspect of this disclosure, a 3D printer includes a printhead configured to receive filament material from a filament assembly. A spool cabinet of the 3D printer provides a chamber configured to have filament spools positioned therein and to provide a controlled environment for the filaments on the filament spools. The 3D printer includes a base located outside the chamber, configured to receive a spool chip housing for the filament spools to hold the spool chips outside the controlled environment of the chamber.

[0035] In another aspect of this disclosure, the spool cabinet includes a door that, when closed, covers the chamber and the base. A gasket for the door is sealed to the frame of the spool cabinet. In an embodiment where the spool chip housing is attached to the filament spool via a tether, a portion of the tether extends between the gasket and the frame. In another aspect, the base of the 3D printer includes a notch positioned to allow the tether to be guided out of the spool chip housing when it is located in the base.

[0036] On the other hand, the 3D printer's base includes a spool chip interface located therein, which is configured to read data from the spool chip, write data to the spool chip, or otherwise interact with the spool chip. The 3D printer includes a controller configured to control the printing operation of the 3D printer, wherein the controller communicates with the spool chip via the spool chip interface.

[0037] In another aspect of some embodiments, the base is configured to receive a removable handle of a filament spool including a spool chip housing. The base may include a latch receiving structure configured to receive a latch insertion member of the removable handle to releasably secure the handle within the base. Attached Figure Description

[0038] Figure 1 This is a front view of a 3D printer configured to print 3D parts and support structures using one or more filament components disclosed herein.

[0039] Figure 2 yes Figure 1 The diagram shows a front view of the 3D printer.

[0040] Figure 3 yes Figure 1 The image shows a front view of the spool cabinet of a 3D printer.

[0041] Figure 4 This is a perspective view of an embodiment of the consumable components disclosed herein.

[0042] Figure 4A yes Figure 4 The diagram shows a perspective view of a consumable assembly, wherein, according to some embodiments, the filament guide is snapped into a filament keychain.

[0043] Figures 5 to 7 yes Figure 4 The exploded and perspective views of the detachable filament keychain of the consumable component shown are optionally in the form of a handle.

[0044] Figure 7A yes Figure 7 The diagram shows a perspective view of a filament keychain, in which a filament guide is inserted into the filament keychain.

[0045] Figures 8 to 10 yes Figure 3 The view of the spool cabinet shows the process of installing consumable components.

[0046] Figure 11 It is based on Figures 8 to 10 The flowchart shows a representative method of the process. Detailed Implementation

[0047] This disclosure relates to a consumable assembly for a 3D printer, wherein, for example, the consumable assembly includes a spool and a data tag, the spool being configured to retain a supply of consumable filament material, and the data tag including information about the filament. The consumable assembly includes a spool chip or electronic spool identification component, such as an E-PROM chip or RFID tag, tethered to the spool. The spool chip of the consumable assembly contains identification data and / or other data of the consumable assembly. The spool is configured to be mounted in a spool cabinet of the 3D printer, and a housing of a filament data key or filament key card is configured to be received in a base of the 3D printer outside the spool cabinet and to communicate with the 3D printer from within the base. Typically, the spool cabinet has a controlled (e.g., heated and / or dehumidified) environment within the printer, and the spool chip is heat-sensitive. A tether of the consumable assembly attaches the filament data key to the spool and continues to attach the device to the spool when the spool chip is received in the base outside the spool cabinet. The geometry of the filament key card retains it in the base.

[0048] In some embodiments, the housing of the filament data key is configured to be attached separately to the spool before and / or after use. In these embodiments, after the spool is installed into the chamber of the spool cabinet, the spool chip housing can be removed from the spool but remains attached to it by a tether. After the spool is installed into the cabinet, the spool chip is inserted into the base of the 3D printer located outside the chamber to keep the spool chip outside the controlled (e.g., heated) environment within the chamber.

[0049] In some embodiments, the spool chip is held in a housing that is attached to and detached from the spool, while maintaining a separate connection to the spool via a tether. Attaching the spool chip housing to the spool reduces the likelihood of tether tangling and device jamming during spool installation and removal. The housing can be configured to additionally function as a handle for the spool. For example, the spool chip housing is configured to attach to a sidewall or flange of the spool to provide a surface for gripping and manipulating the spool to a location within or near the 3D printer, and can be detached from the spool once it is installed in the 3D printer, allowing the spool to rotate to dispense filament for printing 3D parts or associated support material. The spool chip housing configured as a handle can be reattached to the spool after use so that a warm spool can be removed from the machine using a cool-to-the-touch handle.

[0050] The spool chip may include and transmit to the printer information about the material type, filament diameter, and / or remaining length of filament on the spool, as described, by way of non-limiting example, in Stratasys U.S. Patent No. 6,022,207 and MakerBot U.S. Patent No. 9,233,504, the contents of which are incorporated herein by reference in their entirety. The spool chip may be any electronically readable device, such as an electronically readable and writable circuit board or an erasable programmable read-only memory (EPROM) device. The spool chip may be configured to store and update data, specifications, and other information about the filament wound on the spool. The spool chip acts as a data tag and may include a variety of functions. For example, the characteristic data stored on the spool chip may include at least one of the following: material identification number, build material type, build material diameter, extruder temperature requirement, build material melt temperature, build material color, build material color batch number, build material unit cost, build material density, build material tensile strength, build material viscosity, build material recycling code, build material expiration date, or other characteristic information suitable for 3D printers. The spool chip can also be used to track the linear feet of the filament on the spool. The data can include non-executable code containing information such as the length of the remaining filament on the spool, material type, average outer diameter of the filament, batch number, number of times the spool has been loaded into the 3D printer, and the storage conditions required to hold the filament spool in the cabinet. The 3D printer can query the spool chip to verify spool material information and OEM confirmation, track the length or volume of material extracted from the spool during printing, or verify or monitor other data related to the material on the spool. As the filament is fed into the extruder, the printer tracks the amount of material released from the spool or commands the amount of material to be extruded and subtracts that amount from the total on the machine. The 3D printer can then write back to the spool chip to update the stored information. On the other hand, the spool chip can encode a unique identifier for the filament component, which can be used by the printer, for example, in conjunction with remote network resources, to determine the properties of the build material, thereby further determining the operating parameters of the manufacturing process using the build material. The printer can use material type information to configure machine parameters suitable for manufacturing parts with that specific material.

[0051] Various types of consumable components can be used to supply wound filaments in embodiments of this disclosure. The terms used herein to describe containers for consumable filament materials include spools, containers, cans, tubes, etc. Unless explicitly provided otherwise or clearly apparent from the context, all such terms are intended to refer to containers, etc., that typically contain and wind filament material and supply such material to a 3D printer as consumable printing material.

[0052] Consumables used for 3D printing have previously included electronic devices (sometimes referred to as "spool chips" or "spool tags") that maintain and provide filament data to the 3D printer in various ways. A spool chip can be any device or combination of devices suitable for storing data related to the filament material. For example, this can include radio frequency identification (RFID) tags (e.g., active or passive RFID tags), optically identifiable tags (e.g., barcodes, quick-read (QR) codes, etc.), magnetically identifiable tags (e.g., magnetic stripes), or any other tag that can be automatically detected and associated by a controller to identify material information on the spool. Sensors that read data from the spool chip can automatically identify the filament material and provide the controller with data about the type of build material, etc. For example, as disclosed in U.S. Patent No. 7,063,285, the spool can be contained within a consumable assembly, and the spool chip can be mounted onto the consumable assembly. For example, as disclosed in U.S. Patent No. 9,073,263, the spool can be assembled within a consumable assembly and further encapsulated with an associated printhead including the spool chip. Once the filament is installed in the printer, sensors or readers on the 3D printer automatically read the spool. In other prior filament assemblies, such as those disclosed in U.S. Patent No. 7,938,351, the filament spool is supplied with a separate assembly containing a spool chip (through which the filament is initially supplied). The user passes the filament through the assembly, then arranges the spool and assembly into a material container, and loads the material container into the 3D printer for operation. Because assemblies containing spool chips can all look identical, and different filament materials can have different usage specifications stored on the spool chip, the loss of an unattached chip assembly or an unexpected mismatch between the chip assembly and the material on the spool can lead to part errors and / or malfunction of the filament assembly. This disclosure prevents this potential problem by connecting the spool and the removable spool chip together, optionally forming a handle from the spool chip housing, and a tether.

[0053] While exemplary embodiments are described with reference to a tethered spool chip housing or a filament keychain (which may also serve as a handle), it is not required that the spool chip housing also serve as a handle, nor is it required that the spool chip housing be attached to or secured to the spool independently of the tethering connection. Furthermore, in some embodiments, the handle is tethered to the spool, but it is not required that the handle contain a spool chip.

[0054] Filament materials may include, for example, acrylonitrile butadiene styrene (“ABS”), polycarbonate, nylon, composite materials, filler materials, support materials, or any other suitable plastic, thermoplastic, or other material that can be effectively extruded to print objects. In some embodiments, the environment in which the spool and filament are held is at high temperatures, which may damage or destroy the spool chip (e.g., a memory chip). For example, the types of materials contained on the spool may include high-temperature thermoplastic resin materials (e.g., Nylon 12, PC, ASA, and Ultem 9085, PES, PPSU, PEKK, and PEI); continuous carbon fibers; or a core / shell combination of fiber and resin. These materials may be maintained at temperatures above 100°C to ensure that the filament does not absorb moisture during storage or printing. Since the spool chip is held within the spool chip housing, optionally, in the disclosed embodiments, the spool chip housing is configured as a handle that can be removed from the spool, so that the removed housing or handle can be left in a location outside the optional heated environment to protect the chip while allowing the 3D printer to read and use information. However, the handle does not need to include a spool chip or other electronic equipment in all embodiments; conversely, in embodiments that include a spool chip, the spool chip housing does not need to form the handle in all embodiments. In embodiments with a tethered handle, regardless of whether the handle includes a spool chip, storing the handle outside the heated environment allows the operator to retrieve the handle, which is maintained at ambient conditions or a "touch-safe" temperature below 60°C, and use the handle to remove the heated spool without waiting for the spool to cool to a temperature tolerable to the operator's hand. Even if the spool cabinet 52 is not maintained at a high temperature, the handle will still provide a convenient and beneficial method for removing the spool after use, as material spools are often very heavy and can become recessed into the spool compartment, making them difficult to remove, especially at high temperatures. The spool chip and housing are also referred to herein as a filament keychain.

[0055] A handle or filament keychain is configured to snap and release, for example, attached to the outer peripheral edges (also called flanges) of the two sidewalls of the spool, as a convenient way to pick up the spool. When the handle is held, the spool is stationary relative to the handle, which allows the spool to be loaded into a carriage in the 3D printer or positioned near the 3D printer. After the spool is loaded into the carriage, the handle is removed to allow the spool to rotate about the axis to dispense the filament. In embodiments where the handle includes the spool chip, the handle is then inserted into a socket or port in the carriage outside of any heated environment, which is configured to read information on memory and signal to the controller to provide the information contained in the memory. In some embodiments, if the handle is not located in the port, the 3D printer will not recognize the loaded spool and will not allow the 3D printer to use the spool in the printing operation. In other embodiments, the 3D printer will recognize the spool chip even if it is not located in the port, for example, using an RFID chip with near-field communication.

[0056] This disclosure can be used with any suitable extrusion-based 3D printer. For example, Figure 1 and Figure 2 The diagram shows a front view and a frontal schematic of a 3D printer 10, which has a generally horizontal printing plane, wherein the printed parts are indexed in a generally vertical direction when parts are printed layer by layer using two print heads 18. The 3D printer 10 shown uses one or more filament assemblies 12, each of which is an easily loadable, removable, and replaceable spool that maintains a supply of consumable filaments for printing using the 3D printer 10. Typically, one filament assembly 12 contains part material filaments, while the other contains support material filaments, and each filament assembly supplies material to one of the print heads 18. However, the two filament assemblies 12 can have identical structures.

[0057] Each printhead 18 is an easily loadable, removable, and replaceable device comprising a housing that accommodates a liquefier assembly 20 having a nozzle tip 14. Each printhead 18 is configured to receive consumable material, melt the material in the liquefier assembly 20 to produce molten material, and deposit molten material from the nozzle tip 14 of the liquefier assembly 20. Examples of liquefier assemblies suitable for printhead 18 include those disclosed in U.S. Patent No. 6,004,124 to Swanson et al., U.S. Patent No. 7,604,470 to LaBossiere et al., U.S. Patent No. 7,625,200 to Leavitt, and U.S. Patent No. 8,439,665 to Batchelder et al. Other suitable liquefier assemblies include those disclosed in U.S. Patent Nos. 9,327,447 and 10,131,131; and those disclosed in PCT Publication No. WO2016014543A.

[0058] The conduit 16 interconnects the filament assembly 12 and the print head 18, wherein the drive mechanism of the print head 18 (or 3D printer 10) pulls a continuous segment of consumable filament from the filament assembly 12 through the conduit 16 to the liquefaction assembly 20 of the print head 18. In this embodiment, the conduit 16 may be a component of the 3D printer 10, rather than a sub-component of the filament assembly 12. In other embodiments, the conduit 16 is a sub-component of the filament assembly 12 and may be interchangeable with and from each filament assembly 12 to and from the 3D printer 10. During build operations, the continuous segment of consumable filament driven into the print head 18 is heated and melted in the liquefaction assembly 20. The molten material is extruded in a layered pattern through the nozzle tip 14 to produce a printed part.

[0059] 3D printer 10 uses layer-based additive manufacturing technology to print 3D parts or models and corresponding support structures (e.g., 3D parts 22 and support structures 24) from part and support material filaments of consumable assembly 12, respectively. Exemplary 3D printer 10 prints parts or models and corresponding support structures from filaments supplied by consumable assembly 12 by extruding a path of molten material along a toolpath. During build operations, a continuous segment of consumable filament is driven into an appropriate printhead using a filament driver, wherein the filaments are heated and melted in a printhead liquefaction chamber. The molten material is extruded in a layered pattern through the nozzle tip of the printhead to produce a printed part. In some embodiments, the printhead moves in a plane, and a build platen moves along a print axis to print the part and support structure. In other embodiments, a three-dimensional toolpath may be utilized. In some embodiments, a robot moves with five or more degrees of freedom to print the part. Typically, the printer prints part material and support material, and each consumable assembly supplies part material filaments or support material filaments to a printhead designed for printing part material or support material, respectively. The 3D printers available for 3D printer 10 include an extrusion-based system developed by Stryker Corporation (trademarked as “FDM”), located in Eden Prairie, Minnesota (MN).

[0060] As shown in the figure, the 3D printer 10 includes a system housing 26, a chamber 28, a pressure plate 30, a pressure plate gantry 32, a head support 34, and a head gantry 36. The system housing 26 is a structural component of the 3D printer 10 and may include multiple structural sub-components, such as a support frame, housing walls, etc. In some embodiments, the system housing 26 may include a spool cabinet 52 configured to receive a filament assembly 12. The filament assembly is loaded into a container holder or spool cabinet 52 in which spools and filaments can be preheated and / or dried. Although Figure 1 and Figure 2 Two specific spool cabinets have been selected, but the disclosed embodiments are not limited to any particular number of spool cabinets or the location of the spool cabinets. Chamber 28 is a closed environment containing a pressure plate 30 for printing 3D parts 22 and support structures 24. Chamber 28 can be heated (e.g., using circulating heated air) to reduce the curing rate of the parts and support materials after extrusion and deposition (e.g., to reduce twisting and curling).

[0061] The pressure plate 30 is a platform on which the 3D parts 22 and support structures 24 are printed layer by layer and supported by the pressure plate gantry 32. In some embodiments, the pressure plate 30 may engage and support a build substrate, which may be a tray substrate as disclosed in U.S. Patent No. 7,127,309 to Dunn et al., made of plastic, corrugated cardboard, or other suitable materials, and may also include a flexible polymer film or lining, coated tape, polyimide tape, or other disposable articles for adhering the deposited material to the pressure plate 30 or the build substrate. The pressure plate gantry 32 is a gantry assembly configured to move the pressure plate 30 along (or generally along) the vertical z-axis.

[0062] The head carriage 34 is a unit configured to receive and hold one or two printheads 18 and is supported by the head gantry 36. The head carriage 34 preferably holds each printhead 18 in a manner that prevents or limits movement of the printheads 18 relative to the head carriage 34, such that the nozzle tip 14 remains in the xy build plane, but allows the nozzle tip 14 of the printhead 18 to be controllably moved out of the xy build plane by movement of at least a portion of the head carriage 34 relative to the xy build plane (e.g., servo, switch, or pivot switch).

[0063] In the illustrated embodiment, the head gantry 36 is a robotic mechanism configured to move the head carriage 34 (and the held printhead 18) in a horizontal xy-plane (or substantially in a horizontal xy-plane) above the pressure plate 30. Examples of suitable gantry assemblies for the head gantry 36 include those disclosed in U.S. Patent No. 6,722,872 to Swanson et al. and U.S. Publication No. 2013 / 0078073 to Comb et al.; wherein the head gantry 36 may also support a deformable baffle (not shown) that defines the ceiling of the chamber 28. The head gantry 36 can utilize any suitable bridge gantry or robotic mechanism to move the head carriage 34 (and the held printhead 18), such as using one or more motors (e.g., stepper motors and coded DC motors), winches, pulleys, belts, screws, robotic arms, etc.

[0064] In an alternative embodiment, the pressure plate 30 may be configured to move in a horizontal xy-plane within the chamber 28, and the head carrier 34 (and print head 18) may be configured to move along the z-axis. Other similar arrangements may also be used, such that one or both of the pressure plate 30 and print head 18 are movable relative to each other. The pressure plate 30 and the head carrier 34 (and print head 18) may also be oriented along different axes. For example, the pressure plate 30 may be vertically oriented, while the print head 18 may print the 3D part 22 and the support structure 24 along the x-axis or y-axis.

[0065] System 10 also includes a controller component 38, which may include one or more control circuits (e.g., controller 40) and / or one or more host computers (e.g., computer 42) configured to monitor and operate components of the 3D printer 10. For example, one or more control functions performed by the controller component 38 (e.g., performing mobile compiler functions) may be implemented in the form of hardware, software, firmware, etc., or a combination thereof; and may include computer-based hardware, such as data storage devices, processors, memory modules, etc., which may be external and / or internal features of the 3D printer 10.

[0066] The controller assembly 38 can communicate via communication line 44 with the motors of the print head 18, chamber 28 (e.g., the heating unit of chamber 28), head support 34, pressure plate gantry 32, and head gantry 36, as well as various sensors, calibration devices, display devices, and / or user input devices. In some embodiments, the controller assembly 38 can also communicate with one or more of the pressure plate 30, pressure plate gantry 32, head gantry 36, and any other suitable components of the 3D printer 10. Although a single signal line is shown, communication line 44 may include one or more electrical, optical, and / or wireless signal lines, which may be external and / or internal features of the 3D printer 10, thereby allowing the controller assembly 38 to communicate with various components of the 3D printer 10.

[0067] During operation, the controller assembly 38 can guide the pressure plate gantry 32 to move the pressure plate 30 to a predetermined height within the chamber 28. Then, the controller assembly 38 can guide the head gantry 36 to move the head carriage 34 (and the held printhead 18) in a horizontal xy-plane above the chamber 28. The controller assembly 38 can also guide the printhead 18 to selectively draw continuous segments of consumable filament from the consumable assembly 12 and the conduit 16, respectively.

[0068] although Figure 1 A 3D printer 10 is shown, wherein the build plane lies in a generally horizontal xy plane and the pressure plate 30 moves along the z-direction, which is generally perpendicular to the generally horizontal xy build plane; however, this disclosure is not limited to such a configuration. Figure 1 The 3D printer 10 is shown. Conversely, the filament assembly of this disclosure can be used with any 3D printer, including but not limited to printing on a generally perpendicular printing plane and moving the pressure plate in a direction generally normal to the generally perpendicular printing plane. Regardless of the type of 3D printer used, embodiments of the disclosed filament assembly can be used in filament-based 3D printing systems.

[0069] Now for reference Figure 3The diagram illustrates a single spool cabinet 52 from a system housing 26, where heating or drying is optional. The spool cabinet 52 includes a chamber 54 formed within a cabinet frame 56, and a door 58 connected to the cabinet frame 56 via a hinge 60, allowing the door to be opened and closed to allow insertion or removal of the filament assembly 12. Since the chamber 54 can be heated to preheat the filament assembly to aid the 3D printing process, the door 58 includes a gasket 62 configured to seal against the cabinet frame 56 to help contain heat within the chamber. The spool cabinet keeps the filament dry; some types of filament absorb moisture from the air, resulting in unacceptable print quality. The spool cabinet 52 may also include a spool channel 64 configured to receive the spool of the filament assembly when located within the chamber 54. In addition to the spool channel 64, other filament assembly mounting mechanisms may be included, or alternatives to the spool channel 64. Furthermore, in some embodiments, the spool cabinet 52 also includes a filament guide socket 66, a filament guide (such as...) Figure 9-10 (As shown) can be inserted therein to help guide the filament from the spool into the 3D printer's drive. In some embodiments, the filament guide may include a consumable component.

[0070] In some exemplary embodiments, the spool cabinet 52 also includes a base 68 configured to receive a filament key fob containing a spool chip or spool identification component. The base 68 may include a recess 74 configured to allow wiring tether 206 from the spool chip housing. (See reference...) Figure 4-7 The filament keychain can be inserted into the base 68, where the latch receiving structure 70 interacts with a corresponding component of the device. The base 68 may also include an electronic spool chip interface 72, such as a memory chip interface, configured to read data from, write data to, or otherwise interact with the spool chip of the filament keychain. The base 68 is located outside the heated chamber 54 such that when the door 58 is closed to form a seal between the gasket 62 and the cabinet 56, the device located in the base 68 will remain at a lower temperature (relative to the temperature of the chamber 54) during heating, even if the device is attached to the spool via the tether 206. This allows the filament keychain to remain at a temperature that the operator can touch and also protects any electronic equipment from the high temperatures within the chamber 54. For example, some chip designs cannot be exposed to temperatures above 60°C, but the typical spool cabinet temperature used for heating the filament far exceeds that. In some embodiments, the base 68 is positioned such that when closed to heat the chamber 54, the base and electronic equipment are covered by the door 58. However, in other embodiments, if the printing operation is performed at a temperature below 60°C, the base 68 may be located elsewhere and not covered by the door 58. This disclosure covers one or more spool cabinets and one or more consumable assemblies.

[0071] Now for reference Figure 4 and Figure 4A An exemplary embodiment of a consumable assembly 12 with a spool 200 and a filament keychain 204 is shown, wherein consumable filament 202 is wound on the spool, and the filament keychain includes a spool chip 306 held in a housing and connected to the spool by a tether 206. The tether 206 attaches the filament keychain 204 to the spool and is separated from any device that provides the filament path between the spool and the printer. As an example of the spool chip's included structure, the provided filament keychain 204 is configured as a detachable handle to the spool 200 in the illustrated embodiment. While the exemplary embodiment is described with reference to the filament keychain 204 as a handle, the device 204 could also be any spool chip or electronic device held in a housing but not used as a handle. Figure 4A The illustrated embodiment also includes a filament guide 350, which can be attached to the spool 200 by a snap-fit ​​engagement with the housing of the filament keychain 204.

[0072] The spool 200 includes a pair of spaced-apart spool walls or flanges 208 and 210, a hub 214, a central channel 220 extending longitudinally through the hub, and a shaft 212 held within the central channel of the hub. In an exemplary embodiment, the consumable assembly 12 may include self-aligning features that prevent the spool from being mounted backward or in another misaligned manner. As an example, the consumable assembly 12 may include features that allow the shaft 212 to be inserted into the hub 214 in only one direction. To prevent the shaft from being incorrectly inserted into the spool, the geometry of the central channel 220 and the shaft 212 may render attempts to insert the shaft into the central channel from the spool wall 210 unsuccessful. Examples of such geometry and features are disclosed in U.S. Patent No. 10,422,179 to Koop et al. The spool walls and the hub define a filament winding region 218 for storing wound filaments 202. A tether 206 connects the housing of the spool 212 and the filament keychain 204, such that the tether remains together when the spool wall and hub rotate about the spool and the handle is in the base 68. The tether 206 is thin enough that when the door of the spool cabinet 52 is closed, the door gasket 62 seals against the tether and the frame. In some embodiments, flanges 208 and 210 include recesses 216 configured to receive the ends of the filaments 202 to prevent the filaments from unraveling during storage or transport.

[0073] The exemplary filament keychain 204 is configured for dual use, serving as a handle for 3D printer operators to carry spool 200 to or from the 3D printer, and to load and unload spools from spool cabinet 52. Figures 5 to 7A A filament keychain 204 in an exemplary embodiment is further illustrated. (See example...) Figure 5As best shown in the exploded perspective view, the filament keychain 204 includes a housing, which in the illustrated embodiment includes first and second housing parts 302 and 304. In an exemplary embodiment, these housing parts may be molded plastic parts. A spool chip 306 (an electronic device such as a memory chip) is located in a socket 308 in the first housing part 302, which is positioned adjacent to an electronic device interface 72 of the base 68 when the handle is inserted into the base. A lanyard attachment mechanism 310 is also included in one or both of the first and second housing parts 302 and 304, wherein the lanyard 206 is attached to the mechanism 310. For ease of illustration, Figure 5 Only a portion of the tether 206 is shown. However, the tether 206 must be of sufficient length to maintain attachment to the shaft 212 within the shaft cabinet while allowing the filament keychain 204 to be inserted into the base 68.

[0074] The filament keychain 204 of the illustrated embodiment is configured as a snap-fit ​​handle, which is configured to snap onto the outer peripheral edges of the spool walls 208 and 210 of the spool 200, or snap onto a structure within the base 68. The first and second snap-fit ​​channels 320 and 322 of the filament keychain 204 are in… Figure 7 and Figure 7A The image is best shown in the diagram. A channel 322 is formed between a latch insertion member 312 having a rear tab 314 and a second channel member 324. The latch insertion member 312 includes a tab 326 that locks the filament key clasp 204 into place after the member 312 is inserted into the latch receiving structure 70 of the base 68, or after the outer peripheral portion of the spool wall 208 is received into the channel 322. The rear tab 314 extends through a tab receiving hole 316 of the second handle member 304 to provide a latch release mechanism 318. For example, deflecting the tab 314 with the operator's thumb moves the tab 326 to allow release from the receiving structure 70 of the base 68, or from the channel 322, of the spool wall 208. Figure 7A An optional feature of the filament guide 350 is shown, which snaps into the housing of the filament keychain 204.

[0075] Figures 8 to 10 The process of installing the filament assembly 12 into the spool cabinet 52 of the 3D printer 10 in preparation for printing is illustrated. The spool 200 containing the filament assembly with filament 202 is transported into the spool cabinet. For example, although any method can be used to transport the spool 200, it is preferred that the spool be carried by a filament keychain 204, which is releasably secured to the spool walls 208 and 210. With the door 58 in the open position, the spool is inserted into the chamber 54, where the spool 212 is located in the spool channel 64. Figure 8The location of the spool is shown, with the filament keychain 204 still attached to the spool walls 208 and 210, and the handle connected to the spool 212 (or another location on the spool 200) via a cord 206.

[0076] Now for more specific reference Figure 9 When the spool is inserted into the chamber 54 of the spool holder, the filament guide 350 (in some embodiments, it may accompany the spool 200 in the consumable assembly 12) is inserted into the socket 66 to guide the filament from the spool to the guide tube 16 (e.g., Figure 2 (As shown). The filament guide 350 in socket 66 provides a filament path from near the spool 200 through guide tube 16 to the extruder (e.g., printhead 18) or to the drive mechanism of printhead 18. The filament key 204 is detached from the spool wall, for example by unlocking the filament key handle using latch release mechanism 318. After detaching from its bearing position on the spool wall, the filament key 204 is held connected to the spool 200 by tether 206. The filament 202 is then removed from a notch 216 in one of the spool walls and fed into the guide 350. The filament can then be fed into the 3D printer by advancing it from the spool along a closed filament feed path created by the filament guide 350 and the filament guide tube. Next, as... Figure 10 As shown, the filament keychain 204 is inserted into the base 68, and the latch insertion member 312 is received in the latch receiving structure 70 to secure the filament keychain handle in place. After the filament keychain 204 is inserted into the base 68, the connection point of the tether 206 is located near the notch 74, allowing the tether 206 to extend from the base and upwards to its connection with the spool 200. Inserting the filament keychain 204 into the base 68 allows the filament keychain handle to be stored in a position unaffected by the high temperature of the chamber 54 of the spool cabinet 52. When closed, the door 58, gasket 62, and cabinet frame 56 contain heat from the chamber 54, keeping the filament keychain 204 relatively cool. This allows the operator to safely remove the filament keychain handle by hand when the spool 200 needs to be removed from the spool cabinet. It also provides the operator with a non-heated contact point for gripping the spool in the spool cabinet. In embodiments where the handle incorporates a memory chip or other electronic device, this also protects the device from damage due to exposure to high temperatures.

[0077] After the filament keychain 204 is inserted into the base 68, the base's interface 72 reads data from the spool chip 306 to identify information such as material type, quantity, and required spool chamber temperature. In some 3D printers, the controller assembly 38 will not allow the use of filament from the spool until data from the chip is read.

[0078] After printing, the filament is clamped and the end piece is inserted into the notch 216 on one of the spool walls 208 and 210 for easy storage. The filament keychain 204 is removed from the base 68 by manipulating the latch release mechanism 318 and then reattached to the periphery of the spool wall, preferably on the filament end located in the notch 216, which secures the filament end in place. Using the filament keychain handle, the spool 200 can be removed from the spool cabinet 52 and taken away for storage.

[0079] The above embodiments illustrate a method for processing fused deposition modeled filament spools 200. Figure 11 Flowchart 400 illustrates one such exemplary method embodiment. As discussed, the spool is transported with a spool chip or a filament keychain attached to the spool via a tether. This is indicated in block 402. For example, in some embodiments, the filament spool 200 is carried by a filament keychain 204 configured as a handle and secured to spaced-apart spool walls 208, 210. As discussed, in exemplary embodiments, the handle is also attached to the spool via a tether and may include spool chip or spool identification component electrical equipment. As shown in block 404, the spool is located in a chamber 54 of a spool cabinet 52. In some embodiments including a handle, the handle is used to position the spool in the chamber 54 of the spool cabinet 52, the chamber optionally being of the type that provides heating or other controlled environment to dry the filament wound on the spool. When the spool is in the chamber, the housing of the filament keychain (e.g., the handle) is removed from the spool but remains attached to the spool via a tether. This is indicated in... Figure 11 Box 406 indicates this. As shown in box 408, the tethered spool chip housing is located in a base outside the controlled environment of the chamber. In some exemplary method embodiments, steps 402-408 represent the scope of the method. However, in other embodiments, further steps 410-416 are also included.

[0080] like Figure 11 As shown in box 409, in an embodiment including a filament guide 350 with a spool 200, the user removes the filament guide 350 from the filament keychain 204 and inserts it into the printer's socket 66, then feeds the loose end of the filament into the filament guide 350 to begin feeding the filament to the print head. By design, the filament guide is typically removed before the filament keychain is positioned in the base, but this is not the case in all embodiments. Figure 11As shown in box 410, in some embodiments, when the spool is positioned in the chamber and the handle or other filament keychain is positioned in the base, the spool and filament are heated or otherwise exposed to a controlled environment, while the handle remains at a lower temperature or in a different environment. This can be achieved, for example, by closing the door of the spool cabinet and heating the spool and filament, wherein a tether extends between the door or door seal and the cabinet frame, allowing the handle or other spool chip housing to remain outside the heated environment. In exemplary embodiments, the spool and filament are heated to temperatures above 50 degrees Celsius, and typically above 100 degrees Celsius, to ensure the filament does not absorb moisture, but the handle or spool chip housing remains at a temperature below 50 degrees Celsius.

[0081] When it is necessary to remove the spool from the heated environment of the cabinet chamber, open the door and remove the filament keychain or handle from the base, as follows: Figure 11 As shown in box 412. As shown in box 414, in the example of the handle, the lower-temperature handle is secured to the spool wall, for example, using the snap-fit ​​connection discussed above. In some advantageous embodiments, since multiple filament retaining notches 216 are located around the peripheral edges of the spool walls 208 and 210, the handle is secured to a portion of the spool wall near one of the notches to help manage the cut ends of the filaments. Furthermore, in embodiments using the handle, as shown in box 416, the handle is then used to remove the spool from the cabinet. Additionally, if desired, the filament guide 350 can be reattached to the handle or filament keychain.

[0082] Although this disclosure has been described with reference to preferred embodiments, those skilled in the art will recognize that changes in form and detail may be made without departing from the spirit and scope of this disclosure.

Claims

1. A consumable component for a 3D printer, characterized in that, The consumable component includes: A spool carrying a wound filament, the spool being configured to be mounted in a spool holder, the spool holder being configured to hold the spool in a controlled environment and supply the filament to the print head of the 3D printer via a filament path; A filament keychain, the filament keychain comprising a spool chip retained in a spool chip housing; and A tether, separate from the filament path, connects the filament keychain to the spool and is configured to allow the filament keychain to reach the base of the 3D printer located outside the spool cabinet when the spool is installed in the spool cabinet and the tether remains connected to the spool and the filament keychain.

2. The consumable component according to claim 1, characterized in that, The consumable assembly further includes a filament guide for attaching to the filament keychain during transport and storage.

3. The consumable component according to claim 1, characterized in that, The spool chip housing is configured to be detachably attached to the spool for transport and storage.

4. The consumable component according to claim 3, characterized in that, The spool chip includes an identification device for the consumable component.

5. The consumable component according to claim 4, characterized in that, The spool chip is configured to be received in the base of the 3D printer to position the identification device near the corresponding spool chip interface of the 3D printer.

6. The consumable component according to claim 2, characterized in that, The tether connects the spool chip housing to the spool shaft.

7. The consumable component according to claim 2, characterized in that, The filament keychain further serves as a handle, which is configured to be detachably attached to the spool to allow the spool to be carried by the filament keychain for installation into the spool cabinet of the 3D printer.

8. The consumable component according to claim 2, characterized in that, The spool chip housing is configured to be detachably attached to the edge of the spaced-out wall of the spool.

9. A 3D printer, characterized in that, include: A printhead configured to receive filament material; A spool cabinet having a chamber, the chamber being configured to have filament spools positioned within the chamber and to provide a controlled environment for the filaments on the filament spools; and A base, located outside the chamber of the spool cabinet and configured to receive a spool chip housing for the filament spool, to hold the spool chip outside the controlled environment of the chamber.

10. The 3D printer according to claim 9, characterized in that, The spool cabinet includes a door that, when closed, covers both the chamber and the base.

11. The 3D printer according to claim 9, characterized in that, The spool chip housing is connected to the filament spool by a tether, wherein the spool cabinet includes a door covering the chamber, the door including a gasket sealing to the frame of the spool cabinet, and wherein a portion of the tether extends between the gasket and the frame when the filament spool is located inside the spool cabinet and the spool chip housing is located in the base.

12. The 3D printer according to claim 11, characterized in that, The base includes a notch positioned to allow the tether to be guided out of the spool chip housing when the spool chip housing is located in the base.

13. The 3D printer according to claim 9, characterized in that, The base includes a spool chip interface located within the base, the spool chip interface being configured to read data from or write data to the spool chip.

14. The 3D printer according to claim 9, characterized in that, The spool chip and the spool chip housing include a filament spool hanger, and the base is configured to receive the filament spool hanger.

15. The 3D printer according to claim 9, characterized in that, The filament spool hanger includes a detachable handle to the filament spool, and wherein the base is configured to receive the detachable handle to the filament spool.

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