3D printing filament processing system

Abstract

A 3D printing filament processing system 10 comprising a housing 12 comprising at least one filament input 14; at least one heating element 16 within the housing to soften a 3D printing filament; a se

Description

TECHNICAL FIELD The invention relates to a 3D printing filament processing system. BACKGROUND Three-dimensional (3D) printing, also known as additive manufacturing, is a transformative technology that has revolutionized various sectors, including manufacturing, healthcare, automotive, aerospace, among others. It facilitates the creation of intricate, customized, and precise objects layer by layer from digital models, thereby eliminating the need for conventional manufacturing methods. 3D printing technology employs a range of materials, including polymers, metals, ceramics, and composites, typically supplied in the form of a filament. This filament is fed into a 3D printer, where it is heated and extruded through a nozzle to form the desired object. The quality of the printed object is significantly influenced by the processing of the filament, which includes its heating, melting, and extrusion. Current systems and methods for processing 3D printing filament primarily involve the use of single extruders. These extruders draw the filament through the system, heat it to a melting point, and then extrude it for 3D printing. However, these systems do not involve any intermediate processing or melting of the filament. The filament is heated and melted inside the nozzle in a single step, which can lead to uneven heating and melting, and consequently, inconsistencies in the printed object. Furthermore, these systems are limited in their ability to process multiple filaments simultaneously, which restricts the versatility and complexity of the printed objects. Moreover, the existing systems and methods do not provide for the separation of the filament into multiple strands prior to melting. This limits the control over the melting process and the ability to manipulate the properties of the filament, such as its colour, texture, and strength. In the 3D printing industry, filament is typically melted directly within the nozzle without undergoing any intermediate processing. To address issues like oozing and to boost flow rates, a common solution is to modify the nozzle's dimensions. By making the nozzle longer, there's an increase in the melt zone, which increases flow rate and allows smoother and faster extrusion, however has a considerable downside of increasing oozing and due to the increased length, has negative structural implications. In light of the above, there is a need for improved systems and methods for processing 3D printing filament. These improvements would overcome the shortcomings of the existing implementations and enhance the quality, versatility, and complexity of the 3D printed objects. SUMMARY In general terms, the present disclosure is directed to a system for processing 3D printing filament, which includes at least one heating element to soften the filament, a separator assembly to separate the softened filament into multiple strands, individual melting chambers to melt the strands, a nozzle to combine and extrude the combined molten strands for 3D printing. Advantageously, the invention solves the problem of lack of precision and detail in 3D printed objects caused by larger or longer nozzle systems, by pre-conditioning and melting the 3D printing filament prior to printing, thus enhancing the quality of the final product. According to an aspect of the invention, there is provided a 3D printing filament processing system. The 3D printing filament processing system comprises a housing, at least one heating element disposed within the housing, a separator assembly, individual melting chambers, and a nozzle. The at least one heating element is configured to soften a 3D printing filament. The separator assembly is configured to separate the softened 3D printing filament into multiple distinct strands. The individual melting chambers are downstream of the separator assembly, wherein the distinct strands are melted. The nozzle is downstream of the separator assembly, wherein the molten strands are combined and extruded for 3D printing. Optionally, the individual melting chambers have a curved profile and extend between the filament input and the nozzle. Optionally, the 3D printing filament processing system comprises at least two individual melting chambers extending from the filament input to the nozzle. Optionally, the housing comprises at least two individual melting chambers extending from each filament input to the nozzle. Optionally, each melting chamber has a diameter of between 0.5mm and 5mm. Preferably, each melting chamber has a diameter of 1,75mm, 2.85mm, or 3mm. Optionally, the housing, separator assembly and melting chambers are 3D printed. Optionally, the separator assembly comprises a plurality of adjustable blades to vary the size and number of the distinct strands. Optionally, the nozzle is exchangeable, allowing for different extrusion profiles. Optionally, the 3D printed components of the system are made from a temperature resistant material. Optionally, each pre-melting chamber is equipped with a temperature sensor to monitor and regulate the softening process. Preferably, the temperature sensor is disposed within the housing. Optionally, the system further comprises a combining zone including agitating elements to ensure homogeneity of the combined molten strands. Preferably, the agitating elements comprise a blade assembly. Optionally, the curved profile of the individual melting chambers promotes an even distribution of heat by increasing the length of the flow path within the housing and consequently the time that the filament spends within the melting chamber. Optionally, each melting chamber includes a heating element that can be individually controlled. In other embodiments, the at least one heating element can heat more than one melting chamber. Optionally, the 3D printing filament processing system further comprises a feedback system that adjusts the speed of supply of filament based on the flow rate of the nozzle. According to an aspect of the invention, there is provided a 3D printer. The 3D printer comprises a filament feeder and a 3D printing processing system as previously described. According to an aspect of the invention, there is provided A 3D printing nozzle comprising a body having a filament input and a nozzle outlet, wherein a filament separator is positioned downstream of the filament input and configured to split a 3D printing filament into at least two strands of material, and at least two melting chambers extending between the filament separator and the nozzle outlet. In one embodiment, the at least two melting chambers are curved to extend the length of the filament path between the filament inlet and the nozzle outlet. According to an aspect of the invention there is provided a 3D printing filament processing system, comprising: a housing comprising at least two filament inputs; b) at least one heating element within the housing; a melting chamber extending from each filament input; a nozzle downstream of the melting chamber, wherein the melted filament is combined and extruded for 3D printing. BRIEF DESCRIPTION OF THE DRAWINGS These are and other aspects will now be described in relation to the Figures in which: Figure 1 illustratively shows an external view od a 3D printing filament system according to the present disclosure. Figure 2 illustratively shows a cross section of a 3D printing filament system according to the present disclosure. Figure 3 illustratively shows a 3D printing nozzle according to the present disclosure. DETAILED DESCRIPTION Figure 1 illustratively shows a 3D printing filament processing system (10) according to the present disclosure. The system (10) includes a housing (12). A filament input (14) allows the filament to enter the housing (12). The housing (12) is heated by way of one or more heating elements (16) disposed within the housing (12). The one or more heating elements (16) cause the housing (12) to be heated. The heated housing (12) causes the filament to soften as it enters the housing (12) by way of the filament input (14). A separator assembly (18) is positioned downstream of the filament input (14) and operatively connected thereto. The separator assembly (18) may comprise a series of blades or other separation features to cause the filament to separate into at least two separate strands. Individual melting chambers (20) are positioned downstream of the separator assembly (18) and are configured to melt each individual strand of filament. A nozzle (22) is positioned downstream of the separator assembly (18). The molten distinct strands are then combined before being extruded for 3D printing through the nozzle (18). Advantageously, the system is designed to soften the 3D printing filament to prepare it for the subsequent separation process. This softening process significantly impacts the overall 3D printing process. It makes the filament more pliable and easier to manipulate, reducing the risk of filament breakage and increased pressure buildup overpowering the extruder motors, a common issue that can disrupt the 3D printing process and compromise the quality of the final product. The system (10) achieves this by applying a controlled amount of heat to the filament to soften the filament without causing it to melt or lose its structural integrity. The filament is subsequently melted in the melting chambers (20) before reaching the nozzle (22). The separator assembly (18) is positioned downstream of the filament input (14) and separates the softened filament into multiple distinct strands. The individual melting chambers (20) then take these distinct strands and transform them into a molten state suitable for extrusion. Each melting chamber (20) is heated by at least one heating element (16) that can be precisely controlled to achieve the optimal melting temperature. This ensures that the strands are melted evenly, without any hotspots or cold spots that could lead to inconsistencies in the final product. Furthermore, the melting chambers (20) are designed to maximise the internal surface area of the melting chambers (20) in contact with the filament. In some embodiments, as per Figure 1, a flow combiner (24) is provided to combine the molten strands before reaching the nozzle (22). In some embodiment, as per Figure 2, the molten strands are combined as they enter the nozzle (22). In each case, this results in a filament that is consistent in its composition, which is crucial for achieving a uniform and high-quality 3D print. Finally, the nozzle (22) extrudes the combined molten filament for 3D printing. The nozzle (22) is designed to extrude the filament at a consistent rate, ensuring that the 3D print is formed evenly and accurately. Furthermore, the nozzle (22) can be replaced to control the thickness of the extruded filament, allowing for precise control over the final product's dimensions. In some embodiments the individual melting chambers (20) have a curved profile and extend between the filament input (14) and the nozzle (22). Advantageously, the curved profile of the individual melting chambers (20) serves to increase the overall surface area and prepare the direction of flow to be inline with the nozzle (22) output. The curved design reduces the risk of filament jamming or clogging as can happen in the event of a build-up of pressure when sharp angles are used. This build-up of pressure can cause blockages which can disrupt the 3D printing process. Furthermore, the curved profile can also help to evenly distribute heat across the filament, ensuring a more consistent melting process. This can result in a more uniform and high-quality 3D printed product. In some embodiments the 3D printing filament processing system, as shown in Figure 1, comprises at least two individual melting chambers (20a, 20b) extending from each filament input (14) to the nozzle (22). In other embodiments, three, four, or more, individual melting chambers may extend from filament input (14) to the nozzle (22). Advantageously, having at least two individual melting chambers (20a, 20b) allows for simultaneous processing of multiple filament strands. This can significantly increase the system's throughput, making it more efficient and productive. Additionally, multiple melting chambers (20) can also provide redundancy, ensuring that the system (10) can continue to operate even if one chamber (20) fails or requires maintenance. This design feature enhances the reliability and robustness of the 3D printing filament processing system (10). Notwithstanding the aforementioned advantages, it will be appreciated that in some embodiments, as shown in Figure 2, only a single melting chamber extends from each filament input (14) to the nozzle (22). In some embodiments the 3D printing filament processing system (10) is equipped with a temperature sensor to monitor and regulate the softening process. Advantageously, the inclusion of a temperature sensor in the system (10) allows for real-time monitoring and regulation of the softening process. This can ensure that the filament is always softened to the optimal temperature, enhancing the quality and consistency of the 3D printing process. Furthermore, by continuously monitoring the temperature, the system (10) can quickly respond to any deviations, adjusting the heating process as necessary to maintain the desired temperature. This can prevent overheating or underheating of the filament, both of which can negatively impact the 3D printing process. In some embodiments the curved profile of the individual melting chambers (20) promotes an even distribution of heat. Advantageously, the curved profile of the individual melting chambers (20) can help to promote an even distribution of heat across the filament. This can ensure that all parts of the filament are melted evenly, resulting in a more consistent and high-quality 3D printed product. Furthermore, the curved profile can also help to guide the filament smoothly through the melting chamber (20), reducing the risk of jamming or clogging. In some embodiments the 3D printing filament processing system (10) includes a heating element (16) associated with each melting chamber (12) that can be individually controlled. Advantageously, having a heating element (16) in each melting chamber (20) that can be individually controlled allows for precise temperature regulation for each filament strand. This can ensure that each strand is softened to the optimal temperature, enhancing the quality and consistency of the 3D printing process. Furthermore, individual control over the heating elements (16) can allow for more flexibility in the system (10), as different filament materials may require different softening temperatures. In other embodiments, one or more heating elements (16) are configured to heat the entire housing (12). In some embodiments the 3D printing filament processing system (10) further comprises a feedback system that adjusts the speed of supply of filament based on the flow rate of the nozzle (22). Advantageously, the inclusion of a feedback system that adjusts the speed of supply of filament based on the flow rate of the nozzle (22) can help to optimize the 3D printing process. By continuously monitoring the flow rate of the nozzle (22), the system can adjust the speed of supply of filament to ensure that the supply of molten filament matches the demand. This can prevent the nozzle (22) from running out of filament or being overloaded, both of which can disrupt the 3D printing process and negatively impact the quality of the 3D printed product. As shown in Figure 3, a nozzle for use in 3D printing may comprise a single filament input (14) and multiple melting chambers (20a, 20b) extending from the filament input (14) to the nozzle outlet. It will be understood that the term flow combiner as used herein may refer to a component within the 3D printing filament processing system that is designed to merge the molten strands from individual melting chambers into a single, unified material before it is extruded through the nozzle for 3D printing. It will be appreciated by the person of skill in the art that various modifications may be made to the above-described examples without departing from the scope of the invention as defined by the appended claims.

Claims

1. A 3D printing filament processing system, comprising:a) a housing comprising at least one filament input;b) at least one heating element within the housing to soften a 3D printing filament;c) a separator assembly configured to separate the softened 3D printing filament into multiple distinct strands;d) individual melting chambers downstream of the separator assembly, wherein the distinct strands are melted;e) a nozzle downstream of the flow combiner, wherein the molten strands are combined and extruded for 3D printing.

2. A 3D printing filament processing system according to claim 1, wherein the individual melting chambers have a curved profile and extend between a filament input and the nozzle.

3. A 3D printing filament processing system according to claim 2, wherein at least two individual melting chambers extend from the filament input to the nozzle.

4. A 3D printing filament processing system according to claim 3, wherein the housing comprises at least two pre-melting chambers extending from the filament input to the nozzle.

5. A 3D printing filament processing system according to claim 4, wherein each melting chamber has a diameter that is a division of the overall filament diameter of 1.75mm. 2.85mm. or 3mm.

7. A 3D printing filament processing system according to claim 6, wherein the housing, separator assembly, and melting are 3D printed.

8. A 3D printing filament processing system according to claim 1, wherein the separator assembly comprises a plurality of adjustable blades to vary the size and number of the distinct strands.

9. A 3D printing filament processing system according to claim 1, wherein the nozzle is exchangeable, allowing for different extrusion profiles.

10. A 3D printing filament processing system according to claim 7, wherein the 3D printed components of the system are made from a temperature resistant material.

12. A 3D printing filament processing system according to claim 4, wherein each melting chamber is equipped with a temperature sensor to monitor and regulate the softening process.

13. A 3D printing filament processing system according to claim 1, further comprising a flow combiner that includes agitating elements to ensure homogeneity of the combined molten strands.

14. A 3D printing filament processing system according to claim 2, wherein the curved profile of the individual melting chambers promotes an even distribution of heat.

15. A 3D printing filament processing system according to claim 6, wherein each melting chamber includes a heating element that can be individually controlled.

16. A 3D printing filament processing system according to claim 1, further comprising a feedback system that adjusts the speed of supply of filament based on the flow rate of the nozzle.

17. A 3D printer comprising a filament feeder and a 3D printing processing system according to any of claims 1 to 16.

18. A 3D printing nozzle comprising a body having a filament input and a nozzle outlet, wherein a filament separator is positioned downstream of the filament input and configured to split a 3D printing filament into at least two strands of material, and at least two melting chambers extending between the filament separator and the nozzle outlet.

19. A 3D printing nozzle according to claim 18, wherein the at least two melting chambers are curved to extend the length of the filament path between the filament inlet and the nozzle outlet.

20. A 3D printing filament processing system, comprising:a) a housing comprising at least two filament inputs;b) at least one heating element within the housing;c) a melting chamber extending from each filament input;d) a nozzle downstream of the melting chamber, wherein the melted filament is combined and extruded for 3D printing.

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