A 3D printed structure comprising a 3D printed item and a 3D printed support structure
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- SIGNIFY HOLDING BV
- Filing Date
- 2024-08-13
- Publication Date
- 2026-07-01
Smart Images
Figure EP2024072795_27022025_PF_FP_ABST
Abstract
Description
[0001] A 3D printed structure comprising a 3D printed item and a 3D printed support structure
[0002] FIELD OF THE INVENTION
[0003] The invention relates to a 3D printed structure comprising a 3D printed item and a 3D printed support structure and to a lighting device comprising such an 3D printed structure. The invention further relates to a method of manufacturing such a 3D printed structure by means of 3D printing, in particular by means of fused deposition modelling and to a method for assembling or mounting the 3D printed structure. The invention also relates to a computer program product comprising instructions which, when the computer program product is executed by the 3D printer, cause the 3D printer to carry out the method of manufacturing.
[0004] BACKGROUND OF THE INVENTION
[0005] Digital manufacturing is expected to increasingly transform the nature of global manufacturing. One of the main processes used in digital manufacturing is 3D printing. The term “3D printing” refers to processes wherein a material is joined or solidified under computer control to create a three-dimensional object of almost any shape or geometry. Such three-dimensional objects are typically produced using data from a three-dimensional model, and usually by successively adding material layer by layer.
[0006] Many different 3D printing technologies are known in the art.
[0007] US4575330 discloses a system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed at a selected surface of a fluid medium capable of altering its physical state in response to appropriate synergistic stimulation by impinging radiation, particle bombardment or chemical reaction. With the system, successive adjacent laminae, representing corresponding successive adjacent crosssections of the object, are formed and integrated together to provide a step-wise laminar buildup of the desired object, whereby a three-dimensional object is formed and drawn from a substantially planar surface of the fluid medium during the forming process. This 3D printing technology is known as stereolithography (STL).
[0008] US5121329 discloses an apparatus incorporating a movable dispensing head provided with a supply of material which solidifies at a predetermined temperature, and a base member, which are moved relative to each other along “X”, “ Y”, and “Z” axes in a predetermined pattern to create three-dimensional objects by building up material discharged from the dispensing head onto the base member at a controlled rate. This 3D printing technology is known as fused deposition modeling (FDM).
[0009] FDM, also called fused filament fabrication (FFF) or filament 3D printing (FDP), is one of the most commonly used forms of 3D printing. In an FDM process, a 3D printer creates an object in a layer-by-layer manner by extruding a printable material (typically a filament of a thermoplastic material) along tool paths that are generated from a digital representation of the object. The printable material is heated just beyond solidification and extruded through a nozzle of a print head of the 3D printer. The extruded printable material fuses to previously deposited material and solidifies upon a reduction in temperature. In a typical 3D printer, the printable material is deposited as a sequence of planar layers onto a substrate that defines a build plane. The position of the print head relative to the substrate is then incremented along a print axis (perpendicular to the build plane), and the process is repeated until the object is complete.
[0010] 3D printers are relatively fast, low cost and can be used for printing complicated three-dimensional objects. Such printers are used in printing various shapes using various 3D printable materials. The concept of 3D printing may be useful in many areas, wherein the production of lighting arrangements configured to be mounted in a ceiling (e.g. downlights or spotlight modules) may serve as an example.
[0011] However, when complex structures need to be created using 3D printing, in particular when comprising overhanging structures, supports are required to be able to produce such an overhanging structure. Those supports are not part of the design and need to be manually removed after the printing process is completed. After printing, the supports have no purpose and thus are a waste of material.
[0012] US 2022 / 0355382 Al discloses a product manufactured using additive manufacturing. The product contains a product and a support structure, wherein the support structure is adapted to be removed to provide the product and provides an interface adapted to interact with a counterpart of a tool for removing the support structure.
[0013] SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to at least partly overcome one or more of the aforementioned disadvantages of the prior art, or to provide a useful alternative. In a first aspect, the invention provides a 3D printed structure comprising a 3D printed item and a 3D printed support structure configured to be separated from the 3D printed item, wherein the 3D printed item comprises an overhanging structure, wherein the 3D printed support structure is arranged relative to the overhanging structure such that sagging of the overhanging structure during printing is prevented. The 3D printed item is configured to be assembled or mounted, and wherein, after separation from the 3D printed item, the 3D printed support structure can be used as a tool during assembly or mounting of the 3D printed item.
[0015] The 3D printed structure of this invention comprises a 3D printed support structure which has a secondary function as a tool during assembly or mounting of the 3D printed item. The present invention is advantageous in that the 3D printed support structure, usually being waste, is here a part of the design of the 3D printed structure. The 3D printed support structure is specifically designed together with the 3D item to prevent sagging of an overhanging structure, and to have a function during mounting or assembly of the 3D printed item.
[0016] The 3D printed structure comprising the 3D printed item (also called 3D printed object or 3D item) and the 3D printed support structure may be created by layer-wise depositing (during a printing stage) of a 3D printable material. Herein, the term “3D printable material” refers to the material to be deposited or printed, and the term “3D printed material” refers to the material that is obtained after deposition. These materials may be essentially the same, as the 3D printable material may especially refer to the material in a printer head or extruder at elevated temperature and the 3D printed material refers to the same material, but in a later stage when deposited. The 3D printable material is printed as a filament and deposited as such. The 3D printable material may be provided as filament or may be formed into a filament. Hence, whatever starting materials are applied, a filament comprising 3D printable material is provided by the printer head and 3D printed. Herein, the term “3D printable material” may also be indicated as “printable material”. The term “polymeric material” may refer to a blend of different polymers, but may in embodiments also refer to essentially a single polymer type with different polymer chain lengths. Hence, the terms “polymeric material” or “polymer” may refer to a single type of polymers but may also refer to a plurality of different polymers. The term “printable material” may refer to a single type of printable material but may also refer to a plurality of different printable materials. The term “printed material” may refer to a single type of printed material but may also refer to a plurality of different printed materials. Hence, the term “3D printable material” may also refer to a combination of two or more materials. In general, these (polymeric) materials have a glass transition temperature Tgand / or a melting temperature Tm. The 3D printable material will be heated by the 3D printer before it leaves the nozzle to a temperature of at least the glass transition temperature, and in general at least the melting temperature. Hence, in a specific embodiment the 3D printable material comprises a thermoplastic polymer having a glass transition temperature (Tg) and / or a melting point (Tm), and the printer head action comprises heating the 3D printable material above the glass transition and if it is a semi-crystalline polymer above the melting temperature. In yet another embodiment, the 3D printable material comprises a (thermoplastic) polymer having a melting point (Tm), and the printer head action comprises heating the 3D printable material to be deposited on the receiver item to a temperature of at least the melting point. The glass transition temperature is in general not the same thing as the melting temperature. Melting is a transition which occurs in crystalline polymers. Melting happens when the polymer chains fall out of their crystal structures, and become a disordered liquid. The glass transition is a transition which happens to amorphous polymers; that is, polymers whose chains are not arranged in ordered crystals, but are just strewn around in any fashion, even though they are in the solid state. Polymers can be amorphous, essentially having a glass transition temperature and not a melting temperature or can be (semi) crystalline, in general having both a glass transition temperature and a melting temperature, with in general the latter being larger than the former.
[0017] Using additive manufacturing techniques to manufacture 3D printed structure may permit to co-manufacture the 3D printed item and the 3D printed support structure in a simple way by using the same material or different materials such as but not limited to any plastics and metallics commonly used in additive manufacturing techniques.
[0018] Materials that may qualify as 3D printable materials include, but are not limited to, metals, glasses, (thermoplastic) polymers, and silicones. Especially, the 3D printable material may comprise a (thermoplastic) polymer selected from the group consisting of polystyrenes (such as acrylonitrile butadiene styrene (ABS)), polyamides (such as nylon), polyacetates, polyesters (such as polylactic acid (PLA) and polyethylene terephthalate (PET)), polyacrylates (such as polymethylmethacrylate (PMMA)), polyethylenes (such as low-density polyethylene (LDPE) and high-density polyethylene (HDPE)), polypropylenes, polyvinyl chloride (PVC), polycarbonate (PC), sulfide containing polymers (such as polysulfone), and polyurethanes. The printable material is printed on a receiver item or build plate. Especially, the receiver item can be the printing platform or it can part of the printing platform. The receiver item can also be heated during 3D printing. However, the receiver item may also be cooled during 3D printing.
[0019] A 3D printed support structure, also called support structure or support, is a structure that is created to hold up overhanging or angled parts of a 3D printed item during the printing process. These support structures are usually temporary and are designed to be removed after the printing process is complete. Supporting geometry may typically be (automatically) generated by the slicing software where needed but may also be designed manually in the desired and / or required places. Support structures may typically be made of the same material as the object being printed or may alternatively be made of a material that is easily removable, such as a water-soluble material.
[0020] The 3D printed structure is created by layer-wise depositing of a 3D printable material. When a 3D printer creates an object layer by layer, it may be challenging to print parts of the 3D printed item that are not directly connected to the build plate of the 3D printer. These parts may be hanging in the air or at an angle, and without support structures, may collapse or warp during printing. Thus, one or more supports may be necessary to prevent the 3D printed item from collapsing or warping during the printing process and to ensure that the 3D item maintains its intended shape.
[0021] A support according to the invention, which is designed to have a function during assembly or mounting, may not need to be detached or removed at the production line. Designed supports may be intended to be detached from the 3D printed item by the end user, thus providing the advantage that the amount of manual labor required during production is reduced.
[0022] An overhanging structure or simply overhang in the context of this invention refers to a section of the 3D printed object that extends horizontally or at a large angle from the 3D item without any support underneath it. Typically, an overhanging structure with an angle below 45° may be able to support itself, while an overhanging structure having an angle larger than 45° may need support. To which extent an overhang may be able to support itself may additionally depend on factors such as the 3D printable material and the printing conditions. At a certain point, the weight of the overhang will overcome the stiffness of the material, causing the overhang to droop, sag, or collapse.
[0023] The 3D printed item of this invention is configured to be assembled or mounted. Assembly of the 3D printed item may comprise putting together multiple parts or components to create a larger, more complex object, for example by aligning, attaching, and fastening different parts together to create a finished product. At least one of the multiple parts or components may be the 3D printed item. Alternatively, the 3D printed item itself may comprise multiple parts or components which are to be put together. Mounting of the 3D printed item may comprise attaching, securing, fastening or fixing the 3D printed item to a surface or structure.
[0024] The 3D printed support structure of this invention can be used as a tool during assembly or mounting of the 3D printed item. A tool in the context of this invention needs to be interpreted as any kind of structure, device or object that is configured to perform a specific task during the assembly, mounting, or installation of the 3D printed item. Further aspects of using the 3D printed support structure as a tool are described in more detail below.
[0025] The 3D printed support structure may comprise a screwdriver, a screwdriver bit, a pry tool, a pick, a pin, a spudger, a wedge, a screw, a bolt, or a nut. The 3D printed support structure may have any form or shape but may especially be shaped as a type of tool commonly used during the assembly, mounting, or installation of items, such as the examples named above.
[0026] The 3D printed support structure may have a first end and a second end. The first end may have a geometry configured to be interfaced with a standard hex bit holder, such as commonly present on manual or electric screwdrivers. The second end may be designed to be interfaced with the 3D printed item during assembly or mounting.
[0027] In other words, the 3D printed support structure may thus be described as a single use installation tool.
[0028] The 3D printed support structure may be a tool to be engaged with an interface on the 3D printed item.
[0029] The 3D printed item may comprise an interface designed to receive the 3D printed support structure. Such an interface may have any form or shape but may for example be a drive of a screw, a shaped cavity, a slot, a groove, or a protrusions on the 3D printed item. The interface may allow torque or force to be applied to it. The 3D printed support structure may be a mating tool for the interface on the 3D printed item.
[0030] The location on the 3D printed item requiring support and the location of the interface on the 3D printed item may be the same location but may also be two separate locations. In other words, the 3D printed support structure may thus already be printed connected with the interface during the print process. Alternatively, the 3D printed support structure may be printed in one location and may be moved to the interface during assembly or installation.
[0031] The 3D printed item may be configured to be assembled or mounted by applying a force and / or torque to the 3D printed support structure, and wherein the 3D printed support structure may be configured to break at a lower force and / or torque than the 3D printed item.
[0032] A 3D printed support structure which breaks at a lower force and / or torque than the 3D printed item when applying a force and / or torque during assembly or mounting may protect the 3D printed item from damage. It may for example provide over-torque or overtightening protection. Especially when assembling or mounting 3D printed items with power tools, the 3D printed items may be damaged due to excessive force and / or torque that is applied. Thus, to prevent damage during assembly, mounting, or installation, the 3D printed support structure may be designed such that it may break before the 3D printed item is damaged.
[0033] The force and / or torque required and applied may depend on a variety of factors, including the size and type of the tool and the interface, the material or materials, the strength of the person the settings of a power tool or screwdriver. Power screwdrivers additionally may have adjustable torque settings, which can allow for precise and controlled application of force.
[0034] The 3D printed support structure may be configured to break during mounting or assembly of the 3D printed item when a force and / or torque is applied which is higher than 5 Nm, such as higher than 10 Nm, preferably higher than 20 Nm.
[0035] Reference through the specification to "break away", "break", "broken", and "breakage" means that the material is not limited to mechanical breakage or any type of mechanical failure or deformation.
[0036] The 3D printed item may comprise multiple parts and the multiple parts may comprise a moveable part configured to be moved by the 3D printed support structure.
[0037] A 3D printed item comprising multiple parts or multiple bodies may allow for greater flexibility and functionality. The multiple parts may be printed to be assembled after the printing process or may be printed in a single piece. At least one of the multiple parts comprises a movable part. A movable part is a component or element of the 3D printed item that can be moved or adjusted in some way, either manually or through some mechanical or electronic means. The movable part may be adjusted or positioned to suit different needs or purposes. Movable parts may include but are not limited to hinges, knobs, levers, wheels, screws, clamps, and gears.
[0038] A movable part comprised by the 3D printed item may be moved in various ways depending on the type of 3D printed item and movable part. The movable part may for example move in a linear motion, a rotational motion, an oscillatory motion, or a translational motion.
[0039] As mentioned above, the 3D printed structure may be manufactured in a single piece.
[0040] Such a 3D printed structure comprising the 3D printed item and the 3D printed support structure may comprise multiple bodies or multiple parts, printed in a single piece in an assembly-free way. The 3D printed structure may be printed in a single piece but may still comprise multiple part that can move with respect to each other.
[0041] Such a 3D printed structure or item may be manufactured using a print-inplace printing technique. This technique may be described as a method of creating 3D printed items with moveable parts that can be printed as a single piece. This technique may enable creating complex mechanisms or complex movable parts all in one go in an assembly-free manner. Putting the multiple parts of the 3D printed item together after printing may not be required. 3D printed items manufactured using print-in-place technology may for example comprise hinges, linkages, and joints to create moving parts.
[0042] 3D printed items designed using print-in-place technology may be designed in various ways and constrains may be mainly related to angles of overhanging structures and gaps between individual bodies interfacing each other.
[0043] In a second aspect, the 3D printed item is a fastening device configured to be clamped into a fastening surface. The fastening device comprises a screw element, a clamp element, and a frame having a locking interface configured to hold a device. The frame has a top side and a bottom side, wherein the screw element is coupled to the frame such that the screw element extends from the bottom side to the top side and is mechanically interfaced with the clamp element. The screw element may be arranged to be operated so as to move the clamp element between a first position and a second position, and the 3D printed support structure is a tool for operating the screw element.
[0044] Current fastening devices are typically mounted into a fastening surface using wire springs, which is labor intensive, expensive, and requires separation for recycling. Additionally, such fastening devices can damage ceilings made of soft materials, such as fiberglass foam. These disadvantages are overcome by the fastening device of this invention, which provides the advantage that it does not require assembly, does require less time for installation, and is by default manufactured using a single type of material.
[0045] The fastening surface is to be understood as a surface into which the fastening device is intended to be clamped or mounted, e.g. a ceiling, a shelf, a floor, a wall, or the like. The fastening device is configured to be clamped into the fastening surface, such as into a hole or opening of the fastening surface.
[0046] The fastening device comprises multiple elements or multiple parts. As described above, the multiple parts may be manufactured in a single piece using print-inplace technology.
[0047] The fastening device comprises a screw element. The screw element may have a head comprising a drive, and a body comprising threads. The drive of the screw element may be designed such that it may be interfaced with the 3D printed support structure during mounting or installation. The threads of the screw may be mechanically interfaced with the clamp element such that operating the screw element moves the clamp element between a first position and a second position. To that end, the clamp element may also have a thread which may be mechanically interfaced with the threads of the screw element.
[0048] The frame has a locking interface configured to hold a device. The locking interface may be a twist-lock interface or a click interface but may alternatively also be any kind of interface which allows the frame to hold a device. The device may thus be mechanically coupled to the frame. Possible devices may include lighting devices, disinfection devices, air purifiers, speakers, sensors, sprinklers, smoke alarms, ventilation, communication devices, or the like.
[0049] The clamp element may comprise a clamp surface. The clamp surface may have the purpose to hold the fastening device by resting on or by clamping to the fastening surface. To this end, the clamp surface may be designed large enough to hold the fastening device and to not damage the fastening surface.
[0050] The frame has a top side and a bottom side. The terms top and bottom may refer to the mounted state when the fastening device is mounted in the fastening surface. The bottom side may refer to the side of the fastening device exposed to the environment or space, typically visible to a person. Whereas the top side may typically be located inside the fastening surface, such as above the ceiling or inside the wall, and out of sight of a person. During the manufacturing process, the bottom side may be the side of the frame which is in contact with or closest to the build plate, whereas the top side may be the side of the frame which is farthest away from the build plate. The 3D printed support structure may be a screwdriver bit configured to be engaged with a drive on the screw element.
[0051] A screwdriver bit typically has a first end and a second end. The first end may have a geometry configured to be interfaced with a standard hex bit holder, such as commonly present on manual or electric screwdrivers. The second end may be designed as a mating tool to be interfaced with a drive on the screw element such that the screw element may be operated using the screwdriver bit.
[0052] The first position may be a mounting position used during mounting of the fastening device and the second position may be a clamping position used when the fastening device is mounted.
[0053] Operating the screw element moves the clamp element between a first position and a second position. During mounting or installation of the fastening device, the clamp element may be moved to a first position. The first position may be a mounting position which enables mounting or installation. Once the fastening device is in position, the clamp element may be moved to the second position. The second position is a clamping position which may position the clamping element such that fastening device is clamped or secured inside the fastening surface.
[0054] The clamp element may be tiltable between a nominal position and an angled position. The screw element may have a screw thread and the clamp element may have a clamp thread. In the nominal position the clamp thread may be interfaced with the screw thread, such that the screw element may be operated to move the clamp element. In the angled position the clamp thread may not be interfaced with the screw thread, such that the clamp element may move freely along the screw element without operating the screw element.
[0055] A clamp element having a nominal position and an angled position may significantly improve the ease and speed of mounting or installing the fastening device into a fastening surface without compromising the functionality.
[0056] When the clamp element is in an angled position, the clamp element may be easily moved up and down the screw to quickly bring the clamp element into a desired position. In a nominal position the clamp element may be operated using the screw element as described above.
[0057] The frame may have an outer perimeter, wherein the screw element may be arranged to be operated so as to move the clamp element from the clamping position to the mounting position by lifting and / or turning the clamp element. The clamp element positioned in the mounting position may be positioned inside the outer perimeter, and the clamp element positioned in the clamping position may extend outside the outer perimeter.
[0058] The fastening device is configured to be clamped into a fastening surface. Clamping the fastening device into a fastening surface may comprise positioning the fastening device inside a hole or opening in the fastening surface. During mounting or installation of the fastening device it may thus be required that the fastening device fits through the hole or opening without elements that extend beyond the outer perimeter of the frame of the fastening device. Once mounted, the clamp element may be required to hold the fastening device in its position, and therefore the clamp element may extend beyond the outer perimeter of the fastening device to rest on or clamp to the fastening surface.
[0059] In a third aspect, the invention provides a lighting arrangement comprising the 3D printed structure according to the second aspect, and a lighting device comprising a light source, wherein the lighting device may be coupled to the locking interface of the 3D printed item.
[0060] As indicated above, the 3D printed structure may be used for different purposes. Amongst others, the 3D printed structure may be used in lighting. The 3D printed item may be a fastening device mounted into a fastening surface and may hold the lighting device, which may be coupled to the locking interface of the fastening device. The lighting device may for example be a downlight, a spotlight, or a lamp holder. The lighting device may be used for many different purposes and in many different environments, such as indoor lighting, outdoor lighting, or automotive lighting.
[0061] In the following, the invention will be described in terms of a method for manufacturing and a method for assembling or mounting the 3D printed structure. All aspects described above for the 3D printed structure are equally applicable to the method of its manufacture and the method of its assembly or mounting.
[0062] In a fourth aspect, the invention relates to a method for manufacturing the 3D printed structure according to the first aspect. The method comprises the step of designing the 3D printed item, wherein the 3D printed item comprises an overhanging structure, and designing the 3D printed support structure, wherein the 3D printed support structure is arranged relative to the overhanging structure such that sagging of the overhanging structure during printing is prevented, and wherein the 3D printed support structure is designed such that it can be used as a tool during assembly or mounting of the 3D printed item. The method further comprises the step of manufacturing the 3D printed structure by a 3D printing technique, wherein the 3D printed item and the 3D printed support structure are comanufactured.
[0063] Manufacturing a 3D printed structure according to this invention requires the step of designing the 3D printed item and designing a 3D printed support structure.
[0064] Items for 3D printing are typically designed using a computer program able to create 3D models, e.g. a CAD software, and a slicer software which slices the 3D model into G-code to be processed by the 3D printer. These two tools may also be combined into one computer program. Support structures are typically automatically generated by the slicing software when overhanging structures exceed certain angles or sizes. For the 3D printed structure of this invention it may not be desired that 3D printed support structures are automatically generated by the slicing software. For the 3D printed structure of this invention it is thus needed to design the 3D printed support structure along with the 3D item. The 3D printed support structure is designed at a position relative to the overhanging structure such that sagging of the overhanging structure during printing is prevented. The 3D printed support structure is further designed such that it can be used as a tool during assembly or mounting of the 3D printed item.
[0065] In a further aspect, the invention provides a method for assembling or mounting the 3D printed structure according to the first aspect. The method comprises the steps of separating the 3D printed support structure from the 3D printed item and mounting or assembling the 3D printed item comprising using the 3D printed support structure as a tool.
[0066] In an example, the 3D printed item may comprise multiple parts of which at least one part may be a moveable part and wherein the 3D printed structure may be manufactured in a single piece. In such an example, mounting or assembling the 3D printed item may additionally comprise the steps of engaging the 3D printed support structure with an interface on the 3D printed item, and applying a tightening force and / or torque to the 3D printed support structure to move the moveable part. The 3D printed support structure may be designed to break at a lower tightening force and / or torque than the movable part.
[0067] In yet a further aspect, the invention relates to a computer program product comprising instructions which, when the computer program product is executed by a computer which is functionally coupled to or comprised by a 3D printer, cause the 3D printer to carry out the method of manufacturing according to the fourth aspect.
[0068] The phrase “printing on a receiver item” and similar phrases include amongst others directly printing on the receiver item, or printing on a coating on the receiver item, or printing on 3D printed material earlier printed on the receiver item. The term “receiver item” may refer to a printing platform, a print bed, a substrate, a support, a build plate, or a building platform, etc.. Instead of the term “receiver item” also the term “substrate” may be used. The phrase “printing on a receiver item” and similar phrases include amongst others also printing on a separate substrate on or comprised by a printing platform, a print bed, a support, a build plate, or a building platform, etc.. Therefore, the phrase “printing on a substrate” and similar phrases include amongst others directly printing on the substrate, or printing on a coating on the substrate or printing on 3D printed material earlier printed on the substrate. Here below, further the term substrate is used, which may refer to a printing platform, a print bed, a substrate, a support, a build plate, or a building platform, etc., or a separate substrate thereon or comprised thereby.
[0069] Layer by layer printable material is deposited, by which the 3D printed item is generated (during the printing stage). The 3D printed item may show a characteristic ribbed structure (originating from the deposited filaments). However, it may also be possible that after a printing stage, a further stage is executed, such as a finalization stage. This stage may include removing the printed item from the receiver item and / or one or more post processing actions. One or more post processing actions may be executed before removing the printed item from the receiver item and / or one more post processing actions may be executed after removing the printed item from the receiver item. Post processing may include e.g. one or more of polishing, coating, adding a functional component, etc.. Post-processing may include smoothening the ribbed structures, which may lead to an essentially smooth surface.
[0070] Instead of the term “fused deposition modeling (FDM) 3D printer” shortly the terms “3D printer”, “FDM printer” or “printer” may be used. The printer nozzle may also be indicated as “nozzle” or sometimes as “extruder nozzle”.
[0071] BRIEF DESCRIPTION OF THE DRAWINGS
[0072] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:
[0073] Figs, la-lb schematically depict some general aspects of a 3D printer and of a 3D printed material;
[0074] Figs. 2a-2c schematically depict a 3D printed structure comprising a 3D printed item and a 3D printed support structure;
[0075] Fig. 3 shows a cross section of an example of a fastening device; Fig. 4 shows a perspective view of an example of a fastening device;
[0076] Figs. 5a-5b show details of a fastening device;
[0077] Figs. 6a-6b schematically depict cross sections of a fastening device configured to be mounted into a fastening surface;
[0078] Figs. 7a-7b schematically depict top views of a fastening device configured to be mounted into a fastening surface;
[0079] Fig. 8 schematically depicts an application.
[0080] The schematic drawings are not necessarily to scale.
[0081] DETAILED DESCRIPTION OF THE EMBODIMENTS
[0082] Fig. la schematically depicts some aspects of the 3D printer 500. Reference 530 indicates the functional unit configured to 3D print, especially FDM 3D printing; this reference may also indicate the 3D printing stage unit. Here, only the printer head 501 for providing 3D printed material, such as an FDM 3D printer head is schematically depicted. The 3D printer 500 may include a plurality of printer heads. Reference 502 indicates a printer nozzle. The 3D printer of the present invention may include a plurality of printer nozzles. Reference 320 indicates a filament of printable 3D printable material 201 (such as indicated above). For the sake of clarity, not all features of the 3D printer have been depicted, only those that are of especial relevance for the present invention (see further also below). Reference 321 indicates extrudate (of 3D printable material 201).
[0083] The 3D printer 500 is configured to generate a 3D item 1 by layer-wise depositing on a receiver item 550, which may at least temporarily be cooled, a plurality of layers 322 wherein each layer 322 comprises 3D printable material 201, such as having a melting point Tm. The 3D printable material 201 may be deposited on a substrate 1550 (during the printing stage). By deposition, the 3D printable material 201 has become 3D printed material 202. 3D printable material 201 escaping from the nozzle 502 is also indicated as extrudate 321. Reference 401 indicates thermoplastic material.
[0084] The 3D printer 500 may be configured to heat the filament 320 material upstream of the printer nozzle 502. This may e.g. be done with a device comprising one or more of an extrusion and / or heating function. Such device is indicated with reference 573 and is arranged upstream from the printer nozzle 502 (i.e. in time before the filament material leaves the printer nozzle 502). The printer head 501 may (thus) include a liquefier or heater. Reference 201 indicates printable material. When deposited, this material is indicated as (3D) printed material, which is indicated with reference 202. Reference 572 indicates a spool or roller with material, especially in the form of a wire, which may be indicated as filament 320. The 3D printer 500 transforms this in an extrudate 321 downstream of the printer nozzle 502 which becomes a layer 322 on the receiver item or on already deposited printed material. In general, the diameter of the extrudate 321 downstream of the nozzle 502 is reduced relative to the diameter of the filament 320 upstream of the printer head 501. Hence, the printer nozzle is sometimes (also) indicated as extruder nozzle. Arranging layer 322 by layer 322, a 3D item 1 may be formed. Reference 575 indicates the filament providing device, which here amongst others include the spool or roller and the driver wheels, indicated with reference 576.
[0085] Reference A indicates a longitudinal axis or filament axis.
[0086] Reference C schematically depicts a control system, such as especially a temperature control system configured to control the temperature of the receiver item 550. The control system C may include a heater which is able to heat the receiver item 550 to at least a temperature of 50 °C, but especially up to a range of about 350 °C, such as at least 200 °C.
[0087] Alternatively or additionally, the receiver plate may also be moveable in one or two directions in the x-y plane (horizontal plane). Further, alternatively or additionally, the receiver plate may also be rotatable about z axis (vertical). Hence, the control system may move the receiver plate in one or more of the x-direction, y-direction, and z-direction.
[0088] Alternatively, the printer 500 can have a head 501 that can also rotate during printing. Such a printer has an advantage that the printed material cannot rotate during printing.
[0089] Layers are indicated with reference 322, and have a layer height H and a layer width W.
[0090] Note that the 3D printable material 201 is not necessarily provided as filament 320 to the printer head. Further, the filament 320 may also be produced in the 3D printer 500 from pieces of 3D printable material.
[0091] Reference D indicates the diameter of the nozzle (through which the 3D printable material 201 is forced).
[0092] Fig. lb schematically depicts in 3D in more detail the printing of the 3D item 1 under construction. Here, in this schematic drawing the ends of the filaments 321 in a single plane are not interconnected, though in reality this may be the case.
[0093] Reference H indicates the height of a layer. Layers are indicated with reference 322. Here, the layers have an essentially circular cross-section. Often, however, they may be flattened, such as having an outer shape resembling a flat oval tube or flat oval duct (i.e. a circular shaped bar having a diameter that is compressed to have a smaller height than width, wherein the sides (defining the width) are (still) rounded).
[0094] Hence, Figs, la-lb schematically depict some aspects of a fused deposition modeling 3D printer 500, comprising (a) a first printer head 501 comprising a printer nozzle 502, (b) a filament providing device 575 configured to provide a filament 321 comprising 3D printable material 201 to the first printer head 501, and optionally (c) a receiver item 550. In Figs, la-lb, the first or second printable material or the first or second printed material are indicated with the general indications printable material 201 and printed material 202, respectively. Directly downstream of the nozzle 502, the filament 321 with 3D printable material becomes, when deposited, layer 322 with 3D printed material 202.
[0095] Figs. 2a-2c schematically depict a 3D printed structure 1 comprising a 3D printed item 100 and a 3D printed support structure 10 and a schematic example of how the 3D printed support structure 10 may be used during assembly or mounting of the 3D printed item 100.
[0096] Fig. 2a shows a 3D printed structure 1 comprising a 3D printed item 100 and a 3D printed support structure 10. The 3D printed item 100 comprises an overhanging structure 110, wherein the 3D printed support structure 10 is arranged relative to the overhanging structure 110 such that sagging of the overhanging structure 110 during printing is prevented. Reference 550 indicates the receiver item of the 3D printer 500.
[0097] The 3D printed item 100 is configured to be assembled or mounted and the 3D printed support structure 10 can be used as a tool during assembly or mounting of the 3D printed item 100. To this end, the 3D printed support structure 10 is configured to be separated from the 3D printed item 100 after printing. After separation from the 3D printed item 100 the 3D printed support structure 10 has an additional second function as a tool during assembly or mounting of the 3D printed item 100. The separation of the 3D printed support structure 10 from the 3D printed item is schematically depicted in Fig. 2b.
[0098] Separation of the two items may not happen directly after completion of the printing process, and may not even happen within the production facility. Separation of the 3D printed support structure 10 and the 3D printed item 100 may be performed by the end user or by an installer when mounting, assembling or installating the 3D printed item 100.
[0099] Fig. 2c schematically depicts an example of how the 3D printed support structure 10 may be used during assembly or mounting. The 3D printed support structure 10 may be designed to be engaged with an interface 120 on the 3D printed item 100. To this end, the 3D printed support structure 10, which has previously been separated from the 3D printed item 100, is brought into physical contact with the interface 120.
[0100] Such an interface 120 may basically have any form or shape but may for example be a drive of a screw, a shaped cavity, a slot, a groove, or a protrusions on the 3D printed item 100. The interface 120 may allow torque or force to be applied to it using the 3D printed support structure 10. The 3D printed support structure 10 may be a mating tool for the interface 120 on the 3D printed item 100.
[0101] In the example depicted in Figs. 2a - 2c, the 3D printed support structure is printed at a location of an overhang 110 requiring support to avoid sagging during printing. In this example, this location is a different location than the location of the interface 120 for using the 3D printed support structure 10 as a tool during assembly or mounting. The interface 110 location and the location of the 3D printed support structure 10 during printing may be two different locations but may also be the same location. In other words, in case the 3D printed item 100 comprises an overhang 110 which may require support during printing, and in case the interface is located within the same overhang 110, then the 3D printed support structure 10 may already be printed connected to or located in the interface.
[0102] The 3D printed item 100 may comprise multiple parts and the multiple parts may comprise a moveable part. The interface 120 may be located on or close to the movable part such that the movable part may be moved by operating the 3D printed support structure 10 when engaged to the interface 120.
[0103] A 3D printed item 100 comprising multiple parts including a moveable part may be manufactured in a single piece, for example using a printing technique referred to as print-in-place printing. Printing multiple parts interfacing each other in one piece may be possible when certain design rules are respected. Those design rules may be mainly imposed by the capabilities of the 3D printer 500 and the 3D printing technique used. They may change with the advancement of technology as well as with certain 3D printing settings, such as the layer height, the printing speed, the material type, the temperature, or the fan speed.
[0104] Design rules may be related to the angle of the overhanging structure and to gaps between the multiple parts interfacing each other. Typically, an overhanging structure 110 with an angle below 45° may be able to support itself, while an overhanging structure 110 having an angle larger than 45° may need support. To which extent an overhang 110 may be able to support itself may additionally depend on factors such as the 3D printable material and the printing conditions. A gap between two individual parts of the multiple parts may be designed in different ways. A gap may have a clearance of more than 0.1 mm, such as at least 0.3 mm, preferably more than 0.5 mm to ensure that the individual parts may be moved freely relative to one another. Alternatively or additionally, the two individual parts interfacing each other may be printed using two different materials specifically suited for this purpose, such as non- miscible materials. Such materials will not adhere to each other and may be easily separated. For example, one part may be printed using PLA and the other may be printed using PETG. Alternatively or additionally, the two individual parts may be printed using a dissolvable support material printed in between the two individual parts. Such a dissolvable support material may be dissolved by using a chemical solution or may be transformed from a solid phase to any other phase in any other way.
[0105] Fig. 3 and fig. 4 depict an example in which the 3D printed item 100 is a fastening device 200 configured to be clamped into a fastening surface 20 (not shown in Fig. 3, shown in Figs. 6a-6b). Fig. 3 shows a cross section of the fastening device and fig. 4 shows a perspective view of the fastening device 200.
[0106] The fastening device 200 comprises a screw element 210, a clamp element 220, and a frame 230 having a locking interface 231 configured to hold a device. The frame 230 has a top side 232 and a bottom side 233. The screw element 210 is coupled to the frame 230 such that the screw element 210 extends from the bottom side 233 to the top side 232 and is mechanically interfaced with the clamp element 220. Operating the screw element 210 moves the clamp element 220 between a first position and a second position, and the 3D printed support structure 10 is a tool for operating the screw element 210.
[0107] The fastening device 200 comprises one or more screw elements 210. The screw element may have a head 211 comprising a drive 120, and the screw element may have threads 212. The drive 120 of the screw element 210 may be designed such that it may be interfaced with the 3D printed support structure 10 during mounting or installation. The threads 212 of the screw element 210 may be mechanically interfaced with the clamp element 220 such that operating the screw element 210 moves the clamp element 220 between a first position and a second position.
[0108] The frame 230 may have a circular shape but may alternatively have other shapes such as a rectangular shape, an oval shape, or a triangular shape. The frame 230 may be a supporting structure configured to hold the device using the locking interface 231. The frame 230 may be an open or hollow structure that at least partly encloses the device. The frame 230 may be optimized for stability and for material usage during the design process, for example by topology optimization. The frame 230 may further be scalable to the size and type of the device it is configured to hold. The frame 230 may hold one device but may also hold multiple devices.
[0109] Figs. 5a-5b show details of a fastening device, more particular an example of a fastening device 200 having a clamp element 220 which may be tilted to switch between a nominal position and an angled position. Fig. 5a depicts the clamp element in a nominal position. Fig. 5b depicts the clamp element in an angled position.
[0110] In the nominal position a clamp thread 222 on the clamp element 220 may be interfaced with a screw thread 212 on the screw element 210. The clamp element 220 may thus have no freedom to move relative to the screw element 210. Only operating the screw element 210 may move the clamp element 220, which is described in detail above. In an angled position the clamp thread 222 may not be interfaced with the screw thread 212. The clamp element 220 may have clearance in respect to the screw element 210. The clamp element 220 may thus move freely along the screw element 210 without the need to operate the screw element 210.
[0111] Figs. 6a-6b schematically depict cross section views of a fastening device 200 configured to be mounted into a fastening surface 20. Fig. 6a depicts the fastening device 200 ready for mounting, positioned below the fastening surface 20. Fig. 6b depicts the fastening device 200 in the mounted state, after it has been mounted into the fastening surface 20.
[0112] The fastening surface 20 may typically be a surface into which the fastening device 200 is intended to be clamped or mounted, e.g. a ceiling, a shelf, a floor, a wall, or the like. The fastening device 200 is configured to be clamped into the fastening surface 20, such as into a hole 21 or opening 21 of the fastening surface 20.
[0113] The frame 230 has a top side 232 and a bottom side 233. The terms top and bottom may refer to the mounted state when the fastening device 200 is mounted in the fastening surface 20. The bottom side 233 may refer to the side of the fastening device which may be exposed to the environment or space, typically visible to a person. Whereas the top side 232 may typically be located inside the fastening surface 20, such as above the ceiling or inside the wall, and out of sight of a person.
[0114] The screw element 210 is mechanically interfaced with, for example rotatably coupled to, the clamp element 220 such that the clamp element 220 may be moved by operating the screw element. The screw element 210 and the clamp element 220 are both integrated into the frame 230. The screw element 210 extends from the bottom side 233 to the top side 232. The drive 120 of the screw element 210 may thus be freely accessible and may be operated from the bottom side 233 during mounting or installation into the fastening surface. Alternatively or additionally, the screw element 210 may have an additional interface 121 at the opposite end of the screw element 210, so that it may also be operated from the top side 232, if so required.
[0115] Operating the screw element 210 moves the clamp element 220 between a first position and a second position. The first position may be a mounting position used during mounting of the fastening device 200 and the second position may be a clamping position used when the fastening device 200 is in a mounted state, positioned inside the fastening surface 20. Fig. 5a shows the clamp element 220 in a mounting position and Fig. 5b shows the clamp element 220 in a clamping position.
[0116] The mounting position and the clamping position are schematically depicted in Figs. 7a and 7b, showing a top view of the fastening device. Fig. 7a depicts the fastening device 200 ready for mounting with the clamping element 220 in a mounting position. Fig. 7b depicts the fastening device 200 with the clamping element 220 in a clamping position.
[0117] The frame 230 may have an outer perimeter 234 running along the outer edge of the frame 230. In a top view of the fastening device 200, the outer perimeter thus describes the largest circumference or contour of the fastening device 200.
[0118] Mounting or installing the fastening device 200 may typically comprise mounting the device into an opening or hole 21 in the fastening surface 20. To ensure that the fastening device 200 is securely mounted, the size of the hole 21 may be adapted to fit the outer perimeter 234 of the fastening device 200. During mounting, the fastening device 200 may thus be required to fit through the hole 21 in the fastening surface 20. No elements of the fastening device 200 may substantially extend beyond the outer perimeter 234 of the frame 230. In the mounted state, the clamping element 220 may rest on or be clamped to the fastening surface 20 and may to this end extend beyond the outer perimeter 234 of the frame 230. Operating the screw element 210 may move the clamp element 220 from the clamping position to the mounting position by lifting and / or by turning the clamp element 220. The clamping element 220 may thus retract to a position within the outer perimeter 234 of the frame 230 when moved from the clamping position to the mounting position.
[0119] Fig. 8 schematically depicts an example of a lighting arrangement 1000, which comprises the 3D printed structure 1, or more specifically the 3D printed item 100, and a lighting device 10 for generating light 11. The lighting device 10 comprises at least one light source and the lighting device 10 is coupled to the locking interface 120 of the 3D printed item 100. The 3D printed item 100 may be configured as one or more of (i) at least part of a lighting device housing, (ii) at least part of a wall of a lighting chamber, and (iii) an optical element. Hence, the 3D printed item 100 may be reflective for light source light 11 and / or transmissive for light source light 11.
[0120] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
[0121] The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined.
Claims
CLAIMS:
1. A 3D printed structure (1) comprising a 3D printed item (100) and a 3D printed support structure (10) configured to be separated from the 3D printed item (100), wherein the 3D printed item (100) comprises an overhanging structure (110), wherein the 3D printed support structure (10) is arranged relative to the overhanging structure (110) such that sagging of the overhanging structure (110) during printing is prevented, wherein the 3D printed item (100) is configured to be assembled or mounted, and wherein, after separation from the 3D printed item (100), the 3D printed support structure (10) can be used as a tool during assembly or mounting of the 3D printed item (100).
2. The 3D printed structure (1) according to claim 1, wherein the 3D printed support structure (10) comprises a screwdriver, a screwdriver bit, a pry tool, a pick, a pin, a spudger, a wedge, a screw, a bolt, or a nut.
3. The 3D printed structure (1) according to any one of the preceding claims, wherein the 3D printed support structure (10) is a tool to be engaged with an interface (120) on the 3D printed item (100).
4. The 3D printed structure (1) according to claim 3, wherein the 3D printed item (100) is configured to be assembled or mounted by applying a force and / or torque to the 3D printed support structure (10), and wherein the 3D printed support structure (10) is configured to break at a lower force and / or torque than the 3D printed item (100).
5. The 3D printed structure (1) according to any one of the preceding claims, wherein the 3D printed item (100) comprises multiple parts and wherein the multiple parts comprise a moveable part configured to be moved by the 3D printed support structure (10).
6. The 3D printed structure (1) according to claim 5, wherein the 3D printed structure (1) is manufactured in a single print-in-place piece.
7. The 3D printed structure (1) according to any one of the preceding claims, wherein the 3D printed item (100) is a fastening device (200) configured to be clamped into a fastening surface (20), wherein the fastening device (200) comprises a screw element (210), a clamp element (220), and a frame (230) having a locking interface (231) configured to hold a device, wherein the frame (230) has a top side (232) and a bottom side (233), wherein the screw element (210) is coupled to the frame (230) such that the screw element (210) extends from the bottom side (233) to the top side (232) and is mechanically interfaced with the clamp element (220), wherein the screw element (210) is arranged to be operated so as to move the clamp element (220) between a first position and a second position, and wherein the 3D printed support structure (10) is a tool for operating the screw element (210).
8. The 3D printed structure (1) according to claim 7, wherein the 3D printed support structure (10) is a screwdriver bit configured to be engaged with a drive on the screw element (210).
9. The 3D printed structure (1) according to any one of claims 7-8, wherein the first position is a mounting position used during mounting of the fastening device (200) and the second position is a clamping position used when the fastening device (200) is mounted.
10. The 3D printed structure (1) according to claims 7-9, wherein the screw element (210) has a screw thread (212) and the clamp element (220) has a clamp thread (222), wherein the clamp element (220) is tiltable between a nominal position and an angled position, wherein in the nominal position the clamp thread (222) is interfaced with the screw thread (212), such that the screw element (210) can be operated to move the clamp element (220), andwherein in the angled position the clamp thread (222) is not interfaced with the screw thread (212), such that the clamp element (220) can move freely along the screw element (210) without operating the screw element (210).
11. The 3D printed structure (1) according to any one of claims 9-10, wherein the frame (230) has an outer perimeter (234), wherein the screw element (210) is arranged to be operated so as to move the clamp element (220) from the clamping position to the mounting position by lifting and / or turning the clamp element (220), wherein the clamp element (220) positioned in the mounting position is positioned inside the outer perimeter (234), and wherein the clamp element (220) positioned in the clamping position extends outside the outer perimeter (234).
12. A lighting arrangement (1000), comprising the 3D printed structure (1) according to any one of claims 7-11, and a lighting device (10) comprising a light source, wherein the lighting device (10) is coupled to the locking interface (120) of the 3D printed item (100).
13. A method for manufacturing the 3D printed structure (1) according to any one of claims 1-10, the method comprising the steps of: designing the 3D printed item (100), wherein the 3D printed item (100) comprises an overhanging structure (110), designing the 3D printed support structure (10), wherein the 3D printed support structure (10) is arranged relative to the overhanging structure (110) such that sagging of the overhanging structure (110) during printing is prevented, and wherein the 3D printed support structure (10) is designed such that it can be used as a tool during assembly or mounting of the 3D printed item (100), and manufacturing the 3D printed structure (1) by a 3D printing technique, wherein the 3D printed item (100) and the 3D printed support structure (10) are comanufactured.
14. A method for assembling or mounting the 3D printed structure (1) according to any one of claims 1-11, wherein the method comprises the steps of: separating the 3D printed support structure (10) from the 3D printed item(100),mounting or assembling the 3D printed item (100) comprising using the 3D printed support structure (10) as a tool.
15. The method according to claim 14, wherein the 3D printed item (100) comprises multiple parts of which at least one part is a moveable part, wherein the 3D printed structure (1) is manufactured in a single piece, and wherein mounting or assembling the 3D printed item (100) additionally comprises the steps of: engaging the 3D printed support structure (10) with an interface (120) on the 3D printed item (100), applying a tightening force and / or torque to the 3D printed support structure(10) to move the moveable part, wherein the 3D printed support structure (10) is designed to break at a lower tightening force and / or torque than the movable part.