Apparatus and method for depositing material during additive manufacturing

Abstract

To provide an apparatus and a method for manufacturing a component via additive manufacturing techniques or processes, such as three-dimensional printing manufacturing techniques or processes.SOLUTION: An additive manufacturing apparatus includes: an extruder configured to receive a material; a work surface extending to define a plane receiving one or more layers of the material; an applicator assembly fixed downstream of the additive manufacturing apparatus; a nozzle coupled to the applicator assembly, and configured to receive the material from an extruder and deposit the material on the work surface; and an actuator configured to displace the work surface in a direction of movement. The direction of movement forms an acute angle with the plane.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Aspects of the present disclosure relate to apparatus and methods for fabricating components, in some embodiments, via additive manufacturing techniques or processes, such as three-dimensional (3D) printing manufacturing techniques or processes (e.g., automotive parts, medical devices, machine parts, consumer products, etc.). [Background technology]

[0002] Additive manufacturing techniques and processes involve the deposition of one or more materials to produce net-shape or near-net-shape (NNS) objects, as opposed to subtractive manufacturing methods that remove material. While "additive manufacturing" is an industry standard term (ASTM F2792), additive manufacturing encompasses various named manufacturing and prototyping techniques, including, for example, freeform fabrication, 3D printing, and rapid prototyping / tooling. Additive manufacturing techniques can be used to fabricate simple or complex components from a wide variety of materials. For example, additive manufacturing can enable the fabrication of freestanding objects based on computer-aided design (CAD) models.

[0003] A particular form of additive manufacturing is commonly known as 3D printing. One 3D printing process, commonly referred to as fused deposition modeling (FDM) or fused layer modeling (FLM), involves melting thin layers of thermoplastic material and applying this material in layers to create the final part. This is accomplished by passing a continuous, thin filament of thermoplastic material through a heated nozzle or by passing the thermoplastic material through an extruder with an associated nozzle, which melts and applies the thermoplastic material to the structure to be printed. The heated material is applied in layers to an existing structure, melting and fusing with the existing material to create a solid, finished part.

[0004] Large parts can be produced during additive manufacturing using two different approaches. In the first approach, material is deposited through a nozzle that faces downward onto a worktable to print the first layer. Subsequent layers are deposited over the contours defined by the first layer to produce the final solid part. In this first approach, the nozzle is moved in a horizontal plane to trace the shape of each layer. The worktable can be moved downward away from the nozzle after each layer is completed to provide a gap for the next layer to be deposited by the nozzle.

[0005] A second approach to producing large parts during additive manufacturing is to utilize a nozzle that moves in the horizontal plane as well as the vertical plane. In this configuration, the nozzle can move downward toward a fixed worktable, move around the worktable to trace the geometry of the printed layer, and move upward away from the worktable to create the gap for the next layer.

[0006] Both of these approaches use a common method that differs from traditional net-shape 3D printing. In net-shape 3D printing, a flowable thermoplastic material is added in thin horizontal layers, with each new layer fused to the previously deposited material to build up the final part shape, layer by layer. If the layers are thin and sufficiently dimensionally accurate, the final net-shape part shape results, which has the advantage that no additional machining or trimming is required. A drawback is that because the layers are thin, many layers are required to build up the part, so this process requires a significant amount of time to perform, especially for large parts. Therefore, it is desirable to reduce the time required to perform this process, which could also reduce manufacturing costs.

[0007] One approach, commonly referred to as near-net-shape, involves depositing material in relatively thick layers (compared to net-shape 3D printing), which results in a final part that is slightly larger than the desired final net shape, and then the part is machined to the final size and shape. The advantage is that this approach can be substantially faster than thin-layer approaches. However, mechanisms or machines are required to perform trimming or machining operations to achieve the final size and shape.

[0008] In 3D printing approaches that require trimming and include a moving worktable, parts can be printed on one machine and trimmed on another. The requirement that vertical movement be achieved by vertically moving the worktable (which may be large) can make trimming with a moving worktable approach impractical for machining operations.

[0009] During a manufacturing operation using another approach with a fixed work table and moving nozzles, both printing and trimming can be performed on the same machine by providing mechanisms to move the print head and trimming head independently of each other on the same work table. Parts are printed with a printing mechanism while a trimming mechanism is away from the work table. Once printing is complete, the printing mechanism is moved away from the work table. Once the printing mechanism is moved away from the work table, a trimming mechanism is then used to machine and trim the printed part to its final size and shape. In this approach, the work table can be fixed, and the printing mechanism and trimming mechanism move on the work table.

[0010] One way to configure a machine to operate in this manner is to center the worktable near the floor and place two walls on either side of the worktable. The top ends of the walls support a linear track with two gantry structures that straddle the wall and travel on tracks. One gantry is equipped with a printing mechanism and the other with a trimming mechanism. In this configuration, parts up to the size of the worktable can be printed using the printing gantry, which can then be machined or trimmed by the trimming gantry to form a solid, finished part.

[0011] In implementing the above-mentioned process, several major disadvantages have arisen. Both of the above-mentioned printing methods, which use either a fixed worktable or a movable worktable, share a common limitation. In each of the two above-mentioned printing methods, the maximum height of a part that can be printed is determined by the maximum number of layers that can be printed, which is limited by the height of the machine. In other words, in both methods, the height of the part is limited by the height of the computer numerical control (CNC) machine. To manufacture long parts, a tall machine is required, which is impractical due to the limitations of typical machine structures and building ceiling heights.

[0012] Furthermore, printing techniques can be limited in the types of parts that can be printed based on the need to use a flat, horizontal surface for the workbench and based on the orientation of the nozzle, e.g., a vertically extending nozzle. Thus, existing methods are limited in that they may be unable to form parts with closed, hollow interiors and / or may be unable to form parts with sloped walls without depositing additional material to form support structures (which are removed after the part is formed). However, the use of support structures increases material costs and complicates the process of manufacturing the part because an extra step is required to remove the support. Furthermore, if the support is removed improperly, the part may be damaged. Summary of the Invention [Means for solving the problem]

[0013] Embodiments of the present disclosure relate particularly to methods and apparatus for fabricating components by additive manufacturing, e.g., 3D printing techniques. Each embodiment disclosed herein may include one or more of the features described in connection with any of the other disclosed embodiments. Exemplary embodiments of the present disclosure include a method for fabricating long parts without increasing the height of the machine. One or more embodiments of the present disclosure include a vertically oriented work platform on wheels or a sliding mechanism located on a fixed horizontal work platform. A conveyor belt independently movable by a servo motor and a gearbox may be located above at least a portion of the fixed horizontal work platform. The vertically oriented work platform is located toward the end of the conveyor belt and the fixed horizontal work platform. A cooling plate, e.g., a liquid-cooled cooling plate, may be present at the leading edge of the horizontal work platform, which may cover the conveyor rollers. A printing mechanism may operate at a location spaced apart from the leading edge of the cooling plate. The printing mechanism can be configured to print each vertical layer so that it is deposited approximately flush with the leading edge of the cooling plate, and the vertical work platform can be moved away from the leading edge of the cooling plate as each new layer is printed. This configuration allows the printing mechanism to operate away from the leading edge of the work platform, with a compression roller (described further below) positioned against the leading edge of the cooling plate. As this process continues, the first layer moves from the trailing edge of the cooling plate onto a conveyor belt attached to the vertical work platform. In an exemplary embodiment of the present disclosure, one or more conveyor belts can be attached to the bottom of a displaceable vertical work platform so that they are displaceable (e.g., slide) across the length of the horizontal work platform. In this manner, the length of the horizontal work platform can be used to print parts.

[0014] The completed solid part can then be separated from the vertical worktable and placed on one or more conveyor belts once the part is fully printed. The vertical worktable can then be decoupled from the one or more conveyor belts and moved in front of a trim area, where a trim gantry can be used to process the part to its desired final size and shape. In some embodiments, the vertical worktable can be completely removed from the machine, and the part can then be machined to its final size and shape. Once machining or trimming is complete, the one or more conveyor belts can retract beneath the stationary horizontal worktable, thereby transporting the completed part from the front or rear of the machine. In one embodiment of the present disclosure, an apparatus for fabricating components through additive manufacturing can include a programmable CNC machine. The CNC machine can include a first worktable oriented along an x-y plane and a second worktable oriented along a y-z plane. At least one conveyor belt can be operatively coupled to the first worktable, and the printing gantry can be mounted on the first worktable. The print gantry can be displaceable along an x-axis of the CNC machine, and the CNC machine can include an applicator having a nozzle configured to deliver a bead of flowable material to the second worktable.

[0015] In another embodiment of the present disclosure, an apparatus for fabricating components via additive manufacturing can include a programmable CNC machine. The CNC machine can include a first worktable oriented along an x-y plane and a second worktable oriented along a plane extending perpendicular to the x-y plane of the first worktable. A printing gantry can be located at a first end of the CNC machine, and the printing gantry can be displaceable along an X-axis of the CNC machine. An applicator can be attached to the printing gantry, and the applicator can include a nozzle that delivers a bead of flowable material to the second worktable. A trimming gantry can be located at a second end of the CNC machine, i.e., opposite the first end, and the trimming gantry can be displaceable along the X-axis of the CNC machine. At least one conveyor belt can extend along the first worktable.

[0016] Embodiments of the present disclosure also relate to an additive manufacturing method. An exemplary method can include applying an adhesive material to a surface of a vertically oriented worktable and depositing a plurality of pellets on the adhesive material. The method can also include depositing a first layer of flowable material from a nozzle of a print gantry onto at least a portion of the plurality of pellets and depositing a second layer of flowable material from the nozzle of the print gantry onto the first layer of flowable material. The method can also include moving the vertical worktable along an X-axis each time a layer of flowable material is deposited.

[0017] In one aspect, an additive manufacturing device comprises an extruder configured to receive material, a work surface extending to define a plane for receiving one or more layers of material, an applicator assembly fixed to a downstream portion of the additive manufacturing device, a nozzle coupled to the applicator assembly, the nozzle configured to receive material from the extruder and deposit the material on the work surface, and an actuator configured to displace the work surface in a direction of movement, the direction of movement forming an acute angle with the plane.

[0018] In another aspect, an additive manufacturing apparatus comprises a work surface extending at an acute angle with respect to the horizontal; an applicator assembly; a nozzle coupled to the applicator assembly, the nozzle defining a longitudinal axis extending perpendicular to the work surface; and a roller configured to compress material deposited on the work surface by the nozzle.

[0019] In yet another aspect, an additive manufacturing method includes receiving a material in an extruder, heating the material in the extruder, and depositing the heated material with a nozzle onto an inclined surface to form a first layer of material, the inclined surface forming an acute angle with a horizontal direction. The method can include parallel moving the inclined surface in a horizontal direction away from the nozzle, and depositing the heated material with the nozzle onto the inclined surface to form a second layer of material.

[0020] As used herein, the terms "comprises," "comprising," or other variations thereof are intended to cover a non-exclusive inclusion of processes, methods, articles, or devices, etc. The term "exemplary" is used in the sense of "example" rather than "ideal." As used herein, the term "extreme" will refer to a component having one dimension that is greater than another dimension, and includes long, tall, wide, etc. As used herein, the terms "approximately" and "about" should generally be understood to encompass ±10% of the stated amount or value.

[0021] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present disclosure, as claimed.

[0022] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary aspects of the disclosure and, together with the description, serve to explain the principles of the disclosure. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a perspective view of an additive manufacturing system including an exemplary additive manufacturing apparatus, according to one or more aspects of the present disclosure. [Figure 2] FIG. 1 is an enlarged perspective view of an exemplary applicator assembly according to one or more embodiments of the present disclosure. [Figure 3] FIG. 1 is a side view of an exemplary vertical work platform and applicator assembly according to one or more embodiments of the present disclosure. [Figure 4] FIG. 4 is an enlarged side view of the exemplary vertical work platform and applicator assembly of FIG. 3. [Figure 5] FIG. 1 illustrates a side view of an additive manufacturing device including an exemplary tilting worktable and tilting mount, in accordance with one or more aspects of the present disclosure. [Figure 6] FIG. 6 is an enlarged side view of the exemplary tilting work platform and tilting applicator assembly of FIG. 5. [Figure 7] 6 is an enlarged side view of the exemplary tilted work platform and tilted applicator assembly of FIG. 5 after depositing multiple layers of material, according to one or more embodiments of the present disclosure. [Figure 8A] FIG. 1 is a cross-sectional view of a layer of material deposited on a tilting work surface, according to one or more embodiments of the present disclosure. [Figure 8B] FIG. 1 is a perspective view of a portion of a part that can be deposited on a tilting work platform according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0024] The present disclosure is directed, inter alia, to methods and apparatus for fabricating parts using additive manufacturing techniques, such as 3D printing. Specifically, the methods and apparatus described herein include methods for producing long parts without increasing the height of the machine. For example, a vertical worktable and a vertically oriented applicator assembly can be used to print long, solid 3D parts along the horizontal axis of the machine, thereby eliminating the need to increase the height of the machine. In some embodiments of the present disclosure, an applicator assembly delivering a flowable material (e.g., a thermoplastic material) can be configured to deliver the material in a vertical, horizontal, or tilted orientation by changing the orientation of the deposition head from a vertical orientation to a horizontal orientation and / or to an tilted orientation between the vertical and horizontal orientations. The deposition head can then print the flowable material, for example, vertically, horizontally, or at an angle onto a suitable surface (e.g., beadboard), as described in more detail below.

[0025] The methods and apparatus described herein can also include methods for producing hollow, fully enclosed parts without the need for forming support structures or infill. For example, the tilted work table and tilted applicator assembly can be used together to deposit multiple layers of material on a surface that is angled relative to the horizontal. The deposited layers can be disposed on a plane or series of planes that form non-zero angles with both the vertical and horizontal directions. For example, each layer can form an angle from about 10 degrees to about 80 degrees with the horizontal.

[0026] The applicator assembly can fix the nozzle at an angle relative to this horizontal plane so that the nozzle is tilted relative to the vertical and also the horizontal during part of the printing process or during the entire printing process. For brevity and clarity, the methods and apparatus are described in the context of fabricating parts from thermoplastic materials. However, the disclosed apparatus and methods can be used with any material suitable for additive manufacturing, particularly any material that is heated to provide a flowable material to a nozzle or other opening for deposition.

[0027] Referring to FIG. 1 , an additive manufacturing apparatus 1, such as a CNC machine, is shown in accordance with an embodiment of the present disclosure. A controller (not shown) can be operatively coupled to the additive manufacturing apparatus 1 to displace a dispensing nozzle 51 along a first horizontal or longitudinal line of motion (x-axis), a second horizontal or lateral line of motion (y-axis), and a vertical line of motion (z-axis) according to a program input or imported into the controller to execute an additive manufacturing process to form a desired component. In some embodiments, the program can be input or imported into a computer to control the apparatus 1 to form elongated 3D printed parts and to perform the functions and methods described herein. The additive manufacturing apparatus 1 can be configured to print or otherwise create 3D parts from digital representations of the 3D parts (e.g., AMF and STL format files) programmed or imported into the controller.

[0028] For example, in an extrusion-based additive manufacturing system, a 3D part can be printed in a layer-by-layer manner from a digital representation of the 3D part by extruding a flowable material. The flowable material can be extruded through an extrusion tip or nozzle 51 included in the system's print head or applicator assembly 43. The flowable material can be deposited as a series of beads or layers on a substrate in the xy plane when the apparatus 1 is configured for horizontal printing. In some embodiments, the xy plane can be used to print long parts without increasing the machine height. The extruded flowable material can be fused to previously deposited material and solidified with a temperature reduction. The position of the print head relative to the substrate can then be incrementally advanced along the z-axis (perpendicular to the xy plane), and this process can be repeated to form a 3D part similar to the digital representation. As described below, by using a vertical worktable and appropriate mounting plate, the apparatus 1 can alternatively be configured for vertical printing (material deposition in the yz plane). In some embodiments, the additive manufacturing apparatus 1 can be configured to deposit material in planes other than the xy plane, and other than the xz or yz planes, allowing hollow parts to be produced without forming support structures, as described below.

[0029] The additive manufacturing apparatus 1 shown in FIG. 1 can include a bed 20, a pair of laterally spaced side walls 21 and 22, a print gantry 23, a trimming gantry 36 supported on the opposing side walls 21 and 22, a carriage 24 attached to the print gantry 23, a carrier 25 attached to the carriage 24, an extruder 61, and an applicator assembly 43 attached to the carrier 25 at a downstream portion of the additive manufacturing apparatus 1 (e.g., the portion of the apparatus 1 downstream of the extruder relative to the flow of material to a nozzle 51 or other structure on which the material is deposited). Above the bed 20 between the side walls 21 and 22 is a horizontal workbench with a support surface. 27 is disposed on the bed 20. The support surface can be disposed in a horizontally extending plane (e.g., the x-y plane) and can be fixed or displaceable along the x-axis and / or y-axis. For example, in a displaceable configuration, the horizontal work platform 27 can be displaceable along a set of rails attached to the bed 20. Displacement of the horizontal work platform 27 can be achieved using one or more servo motors and one or more rails 39 and 40. In an exemplary configuration, the rails 39 and 40 can be mounted on the bed 20 and operatively coupled to the horizontal work platform 27, allowing the horizontal work platform 27 to translate along the X-axis.

[0030] The printing gantry 23 and the trimming gantry 36 are disposed along the Y-axis and supported on the side walls 21 and 22. In FIG. 1 , the printing gantry 23 and the trimming gantry 36 are shown mounted on a pair of guide rails 28 and 29, which are located along the top surfaces of the side walls 21 and 22, respectively. The printing gantry 23 and / or the trimming gantry 36 can be fixedly mounted or displaceably mounted. In some embodiments, the printing gantry 23 and the trimming gantry 36 can be positioned to be displaceable along the X-axis. The printing gantry 23 and the trimming gantry 36 can be displaceable by a pair of servo motors (not shown) mounted on the printing gantry 23 and the trimming gantry 36. Each of the gantries 23 and 36 can be operatively coupled to tracks, e.g., the guide rails 28 and 29, provided on the side walls 21 and 22 of the bed 20. In an exemplary displaceable configuration, one or more servo motors may control the movement of the printing gantry 23 or the trimming gantry 36 , or the movement of both gantries 23 and 36 .

[0031] The carriage 24 may be supported on the print gantry 23. The carriage 24 may include a support member 30 mounted on and displaceable along one or more guide rails, such as guide rails 31, 32, and 33 on the print gantry 23. The carriage 24 may be mounted on the print gantry 23 and displaceable along the Y-axis on one or more guide rails 31, 32, and 33 by a servo motor operatively coupled to the support member 30. The carrier 25 may be mounted on one or more vertically disposed guide rails 35 supported on the carriage 24 for displacement of the carrier 25 relative to the carriage 24 along the Z-axis. The carrier 25 may be mounted on the carriage 24O and displaceable along the Z-axis by a servo motor (not shown) operatively coupled to the carrier 25. A vertical work platform 37 may be attached to conveyor belts 38 and 48. 1 , vertical work platform 37 can be positioned above horizontal work platform 27 and can be displaceable along the X-axis (e.g., by sliding along rails 39 and 40) by one or more servo motors (not shown) coupled to vertical work platform 37 and operatively coupled to tracks, e.g., guide rails 39 and 40, provided on top of bed 20. In some embodiments, guide rails 39 and 40 can be located adjacent to or along the sides of bed 20. In an exemplary displaceable configuration, one or more servo motors can control the movement of conveyor belts 38 and 48, which are actuated to rotate in the same direction to advance vertical work platform 37 along the X-axis.

[0032] As best shown in FIG. 2 , a positive displacement gear pump 74 is mounted to the carrier 25, which can be driven by a servo motor 75 via a gear box 76. The gear pump 74 can receive molten plastic from the extruder 61 shown in FIG. 1 . A compression device, such as a bead shaping roller 59, for compressing the material can be mounted to the carrier bracket 47. The compression roller 59 can be movably mounted to the carrier bracket 47, for example, rotatably or pivotally mounted. The roller 59 can be mounted such that a center portion of the roller 59 is aligned with the nozzle 51. In some embodiments, the roller 59 can be oriented tangentially relative to the nozzle 51. The roller 59 can be mounted relative to the nozzle 51 such that the material, e.g., one or more beads of a flowable material (e.g., a thermoplastic resin), discharged from the nozzle 51 can be smoothed, flattened, leveled, and / or compressed by the roller 59. One or more servo motors 60 may be configured to move, e.g., rotationally displace, the carrier bracket 47 via an arrangement of pulleys or sprockets 56 and a drive chain or belt 65, or by any other suitable means.

[0033] 3, additive manufacturing apparatus 1 (which can form a machine for producing elongated parts without increasing the height of the machine and / or a machine for depositing material at one or more predetermined angles) can include a vertical worktable 37 operatively coupled to rails 39 and 40. Rails 39 and 40 (rail 39 is not shown in FIG. 3) can be located on fixed horizontal worktable 27, as shown in FIG. 1. In some embodiments, vertical worktable 37 can be operatively coupled to one or more independently actuated servo motors and gearboxes configured to translate vertical worktable 37 along the X-axis and along rails 39 and 40.

[0034] The additive manufacturing apparatus 1 may include one or more applicator assembly mounting plates 80 configured to secure the applicator assemblies 43 to the carrier 25. The applicator mounting plates 80 may include a bend or a series of bends such that the applicator assemblies 43 extend in a direction offset by approximately 90 degrees from the vertical along the z-axis. Thus, the nozzles 51 may extend in a horizontal direction ( FIG. 2 ) due to the bends formed in the plates 80.

[0035] Conveyor belts 38 and 48 can be secured to the bottom of vertical worktable 37. Conveyor belts 38 and 48 can be operatively coupled to vertical worktable 37 to advance partially formed or fully formed 3D printed parts along the X-axis. In the exemplary displaceable vertical worktable 37, conveyor belts 38 and 48 can be used to produce long 3D printed parts without increasing the height of apparatus 1 by rotating the desired printed part along the surface of conveyor belts 38, 48 attached to horizontal worktable 27 during operation of apparatus 1. During operation of apparatus 1, long dimension printed parts can be produced along the long axis of conveyor belts 38, 48, which can move the part as additional flowable material is added to further print the part.

[0036] Conveyor belts 38 and 48 may be constructed of stainless steel or other suitable material and may include a suitable coating. In an exemplary embodiment, the bottom surfaces of conveyor belts 38 and 48 may be coated with a polytetrafluoroethylene coating, a non-stick coating, TEFLON® (a registered trademark owned by Chemours), or other suitable material. An exemplary coating may be a friction-reducing coating to facilitate sliding of conveyor belts 38 and 48 across horizontal work surface 27.

[0037] A substrate 45 and a beadboard 46, which form a flat surface, are secured to the longitudinal surfaces of the vertical workbench 37. First, the substrate 45 can be secured to the vertical workbench 37. Then, the beadboard 46 can be secured to the surface of the substrate 45. The substrate 45 and / or the beadboard 46 can be securely attached to each other or to the vertical workbench 37 using a combination of bolts, fasteners, tee nuts, screws, adhesive, or any other suitable fastening device, as shown in FIG. 3 . In some embodiments, the substrate 45 can be formed from plywood, or another suitable material, or combination of materials. In one embodiment, the beadboard 46 can be part of a substructure of, for example, medium density fiberboard (MDF), or premium plywood, or some other suitable material.

[0038] In some embodiments, as shown in FIG. 4 , the bead board 46 can have one side at least partially coated with an adhesive or bonding layer, e.g., adhesive or other suitable material, and infused with thermoplastic bead pellets. While the board 46 is referred to as a “bead” board, it should be understood that the beads are formed by one or more configurations of thermoplastic pellets, and that the material placed on the board 46, such as the thermoplastic material, can have shapes other than beads or pellets. For example, the bead board 46 can include a plurality of regular or irregular shapes, such as particles, spheres, fibers, straight or curved tracks, or any combination thereof, either alone or in combination with the beads or pellets. These materials can be thermoplastic or another type of material that is compatible with the material deposited via the nozzle 51. The application of the adhesive and thermoplastic beads or pellets occurs before printing of the part begins (i.e., before the first layer of thermoplastic material is placed on the bead board 46). The thermoplastic pellet-infused adhesive can provide a weak bond between the printed part and the beadboard 46, and once printing is complete or trimming is complete, the adhesive bond can be broken by applying sufficient force to separate the finished printed part from the underlying structure, such as separating the printed part from the beadboard 46 of the vertical work platform 37.

[0039] In one or more exemplary configurations, the surface of the beadboard 46 can be coated with an adhesive or bonding layer. The bonding layer can include an adhesive, a liquid, a liquid adhesive, or a solidifiable liquid. The bonding layer can include a polyvinyl acetate adhesive (or any other suitable adhesive) and can be first applied to the surface of the beadboard 46 before the beads or pellets are introduced into the board 46. For example, the adhesive or bonding material can be applied to the beadboard 46 with a brush, a roller, or one or more spray nozzles. The pellets can be any suitable material, as shown in deposited form in FIGS. 4 and 6. For example, in one or more embodiments, the pellets can be made of a thermoplastic material. The pellets can be deposited on the adhesive material such that at least a portion of each pellet is in or on the adhesive material when the adhesive material cures or otherwise solidifies, such that the pellets are secured to the adhesive material (and to the beadboard 46). The pellets can be deposited in any suitable uniform or non-uniform pattern.

[0040] When the adhesive cures, the individual beads or pellets can be bonded to the surface of the beadboard 46. Any loose pellets can be removed by any suitable method. For example, loose or otherwise unsecured thermoplastic pellets can be removed by suction with an industrial vacuum cleaner or other suitable device. The resulting prepared pellet bed can extend along the path of the flowable material to be printed, e.g., the first layer of thermoplastic material, as shown in FIG. 4. In an exemplary embodiment, the prepared pellet bed, including the thermoplastic beads of the beadboard 46, can be used to release the final formed article, i.e., the 3D printed part, from the vertical worktable 37, as described above.

[0041] During operation of the additive manufacturing apparatus 1, when a first layer of molten thermoplastic material is deposited onto the layer of bonded pellets on the beadboard 46, one or more beads of hot-deposited material can fuse to the pellets, firmly holding the printed layer of material in place. The adhesive layer, i.e., the glue, can be soft, remaining at least slightly flexible after curing, and can become more flexible when heated by the application of the molten thermoplastic material. Thus, individual pellets can move freely enough to prevent stress buildup between the initial thermoplastic beads and the adhesive layer. In other words, when the first layer of heated molten thermoplastic material is applied onto the prepared pellet bed, the adhesive layer softens, allowing the pellets to move and create a weak attachment to the beadboard 46. Correspondingly, the tendency for the final printed part to deform can be significantly reduced. After the printed structure cools, a force can be applied to the printed part to break the adhesive bond between the printed part and the beadboard 46, and the final printed part can be separated from the underlying structure, e.g., the beadboard 46 on the vertical worktable 37, without damage to the part.

[0042] The above-described process can create a suitable surface for printing a desired article or 3D printed part, which, at least in some embodiments, can reduce the amount of stress induced in the part or article as it cools and solidifies (e.g., due to the presence of the pellets and / or adhesive).

[0043] During operation of additive manufacturing apparatus 1, a molten bead 44 of flowable material (e.g., molten thermoplastic) can be deposited under pressure from a source provided on carrier 25 with extruder 61. Bead 44 can be passed through a positive displacement gear pump 74 using a servo motor 75 and gearbox 76. Pump 74 can deliver the heated flowable material to a vertically oriented applicator 43 and through a nozzle 51, shown with reference to Figures 2 and 3. Vertically oriented applicator 43 can be fixedly or removably coupled to and in fluid communication with nozzle 51.

[0044] As shown in an enlarged view in FIG. 4, as the molten bead 44 exits the applicator 43 through a nozzle 51 (as shown in FIG. 2), the molten bead 44 can be applied to a vertically extending beadboard 46 attached to the vertical worktable 37. A roller 59 can compress the molten bead 44 as the bead of thermoplastic material is deposited on the surface of the beadboard 46. The bead 44 can rest on a cooling plate 42. For example, the leading edge of the cooling plate 42 can be positioned approximately flush with the leading edge of the molten bead 44 (e.g., the cooling plate 42 can be within 0.5 cm or less of the front surface of at least a portion of the bead 44). The cooling plate 42 can be used to cool the molten bead 44 so that it does not stick to or bond with the horizontal support surfaces of the vertical worktable 37 and / or the conveyor belts 38 and 48. The cooling plate 42 can be used to cool the bottom surface of the molded part during operation of the machine 1. The cooling plate 42 can cool the molded part until the part is sufficiently solidified, and ensures that when a portion of the part contacts one or both of the conveyor belts 38 and 48, the part is rigid and does not sag and / or drag on the work table 27. The cooling plate 42 can also be used to ensure that the molded part is properly suspended above the work table 27 by at least the thickness of the conveyor belts 38 and 48.

[0045] The cooling plate 42 can be used to create flat, straight corners where printing will occur, and can be used to cover the conveyor belt rollers 41 to prevent unwanted, uncooled thermoplastic material from the molten bead 44 from entering machinery associated with or surrounding the conveyor belt rollers 41. During operation of the additive manufacturing apparatus 1, the conveyor belt rollers 41 can be configured to move, i.e., advance, one or both conveyor belts 38 and 48.

[0046] In an exemplary configuration of the cooling plate 42, active cooling (e.g., by supplying coolant to the cooling plate 42) can enable printing of flowable materials, such as thermoplastic materials, at temperatures that might otherwise be too high for the conveyor belts 38 and 48 to withstand, allowing for higher printing speeds. After the first layer of thermoplastic material is applied, and before the next layer is deposited, the vertical work table 37 and conveyor belt 38 can be moved away from the applicator assembly 43, which can be vertically oriented a distance equal to the thickness of the first layer of molten bead 44. This process can be repeated for each additional layer of molten bead 44 deposited by the vertically oriented applicator assembly 43 via the nozzle 51 using one or more servo motors and gearboxes. This process can continue until the desired print or part is completed, which can be as long as the entire length of the horizontal work table 27 (see FIG. 1 ). In some embodiments, the part can be longer than the horizontal work table 27. For example, conveyor belts 38 and 48 can move formed parts at least partially off of horizontal work table 27 so that printing can continue.

[0047] The finished print or part can be separated from the vertical work table 37. The printed part can be separated from the vertical work table 37 in one or more processes. For example, one or more screws 49, bolts / fasteners 52, and / or tee nuts 50 can be placed on the surface of the vertical work table 37, the substrate 45, and / or the beadboard 46 to securely attach the vertical work table 37 to the substrate 45 and the beadboard 46 to the substrate 45, as shown in FIG. 4. As shown, the screws 49 or bolts / fasteners 52 can be positioned so that they are not covered by the printed part and can be positioned to attach the beadboard 46 to the substrate 45. The screws 49, fasteners 52, and tee nuts 50 can be sized sufficiently close to the desired printed part so as not to interfere with the trimming operation.

[0048] The substrate 45 and the beadboard 46 can be fabricated from a thick (e.g., 1 / 14 inch or 0.18 cm thick) wood-based material (e.g., plywood, MDF, etc.). Holes in the vertical worktable 37 can be used to attach the substrate 45 to the vertical worktable 37 using tee nuts 50. The beadboard 46 can also be attached to the substrate 45 using screws 49, e.g., drywall screws. The location of the screws 49 can vary, but in some embodiments, the screws 49 can be located as close as possible to where the part will be printed, but not so close that they will contact the trimming fixture of the trimming gantry 36 during the trimming operation. Additionally, the screws 49 can be located far enough away from the intended location of the printed part so that they can be removed without removing the printed part from the beadboard 46. This can allow the beadboard 46 to be separated from the substrate 45 after printing, with the printed part still attached.

[0049] In some embodiments, the substrate 45 may be removably attached to the vertical work platform 37 and / or removably attached to the beadboard 46. Those skilled in the art will appreciate that any other suitable means may be used to fixedly or removably secure the vertical work platform 37 to the substrate 45 and secure the beadboard 46 to the substrate 45. In some embodiments, the bolts / fasteners 52 may be threaded into the tee nuts 50 or bolts / fasteners 52 in the substrate 45 and removed from the backside of the vertical work platform 37.

[0050] In some embodiments, the vertical worktable 37 can be disconnected from the conveyor belts 38 and 48 to remove the finished solid part from the CNC machine 1. The conveyor belts 38 and 48 can be attached to an edge of the vertical worktable 37, such as the lower rear edge of the vertical worktable 37. The conveyor belts 38 and 48 can extend from the lower rear edge to the end of the additive manufacturing apparatus 1, where the conveyor belts 38 and 48 can be wrapped around conveyor belt rollers. The conveyor belts 38 and 48 can then extend from one end of the additive manufacturing apparatus 1 directly below the entire length of the apparatus 1 to the other, where the conveyor belts 38 and 48 can be wrapped around a second conveyor belt roller. The conveyor belts 38 and 48 then extend along the top surface of the horizontal worktable 27 to the lower front edge of the vertical worktable 37, where they are attached to the vertical worktable 37. In other words, conveyor belts 38 and 48 can be attached to opposite ends of vertical work platform 37 and can wrap around horizontal work platform 27 .

[0051] 3 , the cross plate 53 may be displaceable by one or more servo motors and / or gearboxes. The vertical worktable 37 and the conveyor belts 38 and 48 may be attached to the cross plate 53 and displaceable along the cross plate 53. Alternatively, the vertical worktable 37 and the conveyor belts 38 and 48 may instead be attached to the trimming gantry 36 and displaceable along the z-axis of the trimming gantry 36. The finished solid part may be removed from the additive manufacturing apparatus 1 by moving either the cross plate 53 or the z-axis of the trimming gantry 36, which in turn may move the conveyor belts 38 and 48 to transport the finished solid part out of the additive manufacturing apparatus 1, for example, from the left or right side of the additive manufacturing apparatus 1.

[0052] Once detached from the vertical work platform 37, the weight of the finished solid part can hold the part in place for trimming by the trimming gantry 36. The finished part can be removed from the additive manufacturing apparatus 1 using, for example, an overhead crane or hoist attached to the bottom of the printing gantry 23 and / or trimming gantry 36.

[0053] In some embodiments, the cross plate 53 can be used to attach the conveyor belts 38, 48 to the vertical work table 37. The cross plate 53 can be fixed, e.g., bolted, to one or more drive mechanisms that can be located on each side of the additive manufacturing apparatus 1. The vertical work table 37 can be removed from the cross plate 53, leaving the ends of the conveyor belts 38 and 48 attached to the cross plate 53. The conveyor belts 38 and 48 can be releasably fixed to the cross plate 53, and the cross plate 53 can be unbolted and removed from the machine (e.g., drive mechanisms on either side of the apparatus 1). Removing the cross plate 53 can improve access to the additive manufacturing apparatus 1, if necessary.

[0054] During operation of the additive manufacturing apparatus 1, once the final printed part is on the conveyor belts 38 and 48, the vertical worktable 37 can be unbolted or removed from the conveyor belts 38 and 48. The printed part or article can then be moved behind the trimming area and in front of the additive manufacturing apparatus 1 below or near the trimming gantry 36 ( FIG. 1 ) by operating the conveyor belt rollers 41 to advance the conveyor belts 38 and 48 and move the final part away from the print gantry 23 and toward the trimming gantry 36. The trimming gantry 36 ( FIG. 1 ) can then be operated to machine or trim the part to the desired final size and shape. During operation of the additive manufacturing apparatus 1, in some embodiments, the vertical worktable 37 can be completely removed from the CNC machine 1, and the trimming gantry 36 can be used to machine or trim the part to the desired final size and shape. Once machining or trimming of the part is complete, the final trimmed part can be transported from the front or rear end of the horizontal work table 27 by conveyor belts 38 and 48, or lifted or otherwise removed from the CNC machine 1.

[0055] Referring now to FIG. 5 , additive manufacturing apparatus 1 can operate in an additional method of layer-by-layer printing, in which printing occurs at an angle, as opposed to horizontal printing (depositing material from a vertically extending nozzle) and vertical printing (depositing material from a horizontally extending nozzle). In some embodiments, this printing can be performed at an angle of about 10 degrees to about 80 degrees relative to the horizontal. Oblique printing can involve depositing multiple layers on top of each other, with one or more of these layers (or all of the layers) extending in a plane that forms a non-zero angle with the horizontal and a non-zero angle with the vertical. Specifically, oblique printing can be performed such that material is deposited at an angle of about 45 degrees with respect to the horizontal.

[0056] The additive manufacturing apparatus 1 can be configured for tilted printing by first removing the 90-degree applicator mounting plate 80, as described above with respect to FIG. 3. Once removed, the mounting plate 80 can be replaced with a tilted (e.g., about 10 degrees to about 80 degrees) mounting plate 81. In the example shown in FIG. 5, the mounting plate 81 is a 45-degree mounting plate 81 that angles the nozzle 51 downward so that the nozzle 51 presents a longitudinal axis 71 that forms an angle of about 45 degrees with respect to the horizontal. In other configurations, the longitudinal axis 71 of the nozzle 51 can extend through the opening of the nozzle 51 to form an angle of about 10 degrees to about 80 degrees, about 20 degrees to about 70 degrees, about 30 degrees to about 60 degrees, or about 40 degrees to about 50 degrees, when measured with respect to the horizontal.

[0057] In addition to coupling the tilted mounting plate 81, configuring the additive manufacturing apparatus 1 for tilt printing can include removing the vertical worktable 37 ( FIG. 3 ), if present, from the base plate 53. Once the vertical worktable 37 is decoupled from the base plate 53, the base plate 53 can be configured to receive a tilting plate, such as a table plate 83. For example, the table plate 83 can be coupled to the base plate 53 with fasteners, such as bolts. In the configuration shown in FIGS. 5 and 6 , the tilting table plate 83 can be secured to the base plate 53 with a tilt block 82 bolted or otherwise fastened to the front surface of the base plate 53. In some embodiments, the table plate 83 and substrate 45, once coupled to the cross plate 53, can form a desired angle with respect to a horizontal axis (e.g., the x-axis described above, or a direction parallel to the x-axis, such as direction 72). In some embodiments, the angle that the table plate 83 and / or substrate 45 make with the horizontal axis can correspond to the angle of the nozzle 51. For example, table plate 83 and / or substrate 45 may be at a 90 degree angle with the axis defined by nozzle 51, such that axis 71 of nozzle 51 extends perpendicular to inclined plane 70 defined by substrate 46. For example, if nozzle 51 is at a 30 degree angle with respect to the horizontal axis, substrate 46 may be at an angle of approximately 60 degrees with respect to the horizontal axis.

[0058] 5 and 6, the beadboard 46 is attached to a base plate 45, which is bolted to a table plate 83 to connect the beadboard 46 to the cross plate 53. When secured in this manner, the beadboard 46 can be angled at an angle α. Alternatively, the beadboard 46 can be angled at angle α by connecting the beadboard 46 directly to the cross plate 53 or the table plate 83.

[0059] Angle α can be defined by plane 70 and a horizontal direction, such as direction of travel 72, along which the part may be pulled away from applicator assembly 43. In some embodiments, angle α can be an acute angle, and more particularly, an angle of about 45 degrees. Angle α can be from about 10 degrees to about 80 degrees, from about 20 degrees to about 70 degrees, from about 30 degrees to about 60 degrees, or from about 40 degrees to about 50 degrees. As shown in FIG. 6 , angle α can be measured upward from a horizontal axis, such as direction of travel 72, toward the top of plane 70.

[0060] Thus, printing can be performed in orientations other than vertical, where the deposition surface (e.g., work table) extends vertically for use with a horizontally extending nozzle 51, and in orientations other than horizontal, where the deposition surface extends horizontally for use with a vertically extending nozzle 51. As shown in FIG. 6 , the additive manufacturing apparatus 1 can instead define a work surface that extends to an inclined plane 70. For example, this work surface can be configured to receive a bead of material 44 from the nozzle 51. This surface can be, for example, the front surface of a beadboard 46 that extends to the inclined plane 70. As will be appreciated, due to the presence of thermoplastic beads or pellets, a portion of the front surface of the beadboard 46 can extend at a different height (e.g., above or below the plane 70). Thus, use of the term “plane” is not limited to a flat surface, but rather a surface having regular or irregular protrusions, depressions, etc.

[0061] The actuator (e.g., a servo motor as described above) can be configured to translate or otherwise displace the beadboard 46 in a direction of movement 72, which can correspond to a horizontal direction, which can be aligned with or parallel to the X-axis described above.

[0062] As shown in FIG. 6 , the molten bead 44 can be deposited by the applicator assembly 43 using a nozzle 51 by applying the bead 44 to a bead board 46. If the bead 44 is deposited on the board 46, the board 46 can be attached to an inclined substrate 45 on a table plate 83 and an angle block 82. A bead-forming roller 59 can be configured to follow the nozzle 51 and compress the bead 44 while it is supported on the board 46. As shown in FIG. 6 , the bead 44 can rest on a liquid-cooled cooling plate 42 that includes a horizontally extending flat surface. The cooling plate 42 can be flush or nearly flush with the leading edge of the bead 44 and adjacent to the bottom edge of the substrate 46. Thus, the bead 44 can also be cooled by the cooling plate 42 while supported on the surface of the board 46.

[0063] Once the bead 44 is deposited on the substrate 46 (e.g., forming part of a layer or an entire layer of a part), the bead 44 can be pulled backward by the bead board 46. For example, the bead board 46, which includes the bead 44 with one or more beads of thermoplastic material attached thereto, can be pulled in a direction of travel 72 away from the applicator assembly 43. This can be accomplished with actuators (e.g., one or more of the servo motors described above) that move the deposited material onto the conveyor belts 38 and 48, as shown in FIG. 7. The conveyor belts 38 and 48 can transport the part backward, layer by layer, away from the applicator assembly 43 during printing. As shown in FIG. 7, one or more layers deposited by the nozzle 51 can contact the cooling plate 42, which can increase the rate at which each graded layer of material cools.

[0064] When the apparatus 1 is configured for vertical layer printing using a vertically extending nozzle 51, the apparatus 1 can be configured to deposit material to form walls with a maximum angle of approximately 45 degrees. Therefore, it can be difficult to fabricate parts with certain shapes, such as parts forming hollow, closed boxes, without the aid of artificial structures or other supports. To facilitate printing of such structures, the apparatus 1 can be configured for tilted printing, e.g., at 45 degrees. Such tilted printing can enable the fabrication of parts such as boxes and other hollow, closed shapes that can be printed without the addition of any artificial structures, including supports placed below the part, including supports deposited by the additive manufacturing apparatus 1. Thus, the additive manufacturing apparatus 1 can print closed structures without depositing material to form supports.

[0065] In the example shown in FIG. 7 , the part can be deposited as multiple individual layers formed with beads 44 to form a hollow box 84. The box 84 can be printed with a hollow interior and multiple angled layers by using an angled printing configuration of the additive manufacturing apparatus 1. Specifically, each layer of the box 84 can be deposited at an approximately 45-degree angle by using an angled surface, such as the bead board 46 and angled nozzle 51. In the side view of FIG. 7 , the box 84 can be a relatively small hollow box with the final layer printed at a corner of the box. While FIG. 7 shows an example part in the form of a small rectangular box, it will be understood that the additive manufacturing apparatus 1 and board 46 are capable of depositing material to form parts of significantly larger sizes and different shapes. As can be seen from FIGS. 6 and 7 , the part can be transported onto the cooling plate 42 and onto the conveyor belts 38 and 48 for cooling during the printing process, regardless of the part's particular size and shape.

[0066] Figure 8A is a cross-sectional view of a hollow box 84 showing the hollow interior extending into the box 84, including the center of the box 84, that would be formed when printing at an angle such as 45 degrees (or alternatively, any suitable angle as described above). While the box 84 in Figure 7 is shown as including 29 layers of material, Figure 8A shows the box 84 formed with 15 layers. As will be appreciated, a part formed by angle printing with additive manufacturing apparatus 1 may include more or fewer layers compared to either of the exemplary parts shown in Figures 7 and 8A.

[0067] FIG. 8B shows eight layers, or approximately half, of a box 84 as shown in FIG. 8A. Specifically, FIG. 8B shows the box 84 of FIG. 8A sliced ​​diagonally. FIG. 8B also schematically illustrates an approach for depositing multiple layers of material to form a part, such as a box, with a hollow interior. For example, during fabrication of box 84, additive manufacturing apparatus 1 can first form a single, straight layer 85 that extends across a portion of the width of a table or other work surface, such as beadboard 46. Apparatus 1 can then deposit a second layer 86 and multiple subsequent layers 87. Layers 86 and 87 can extend across increasing widths of beadboard 46 and can be deposited on top of previous layers via nozzle 51, such that each newly deposited layer 86 or 87 is supported by the previously deposited layer. In some embodiments, the newly deposited layer 86 or 87 can cover approximately 50% of the previously deposited layer, as viewed from nozzle 51.

[0068] 8B, one or more of layers 86 and / or 87 can be deposited by beginning the placement of material at a corner of box 84, as identified by "START." Once the next corner is reached, the second layer 86 or layer 87 can be deposited by rotating applicator assembly 43 and nozzle 51 approximately 90 degrees. Upon this rotation, applicator assembly 43 and nozzle 51 can move vertically upward (e.g., parallel to plane 70) at a 45-degree angle until the next corner is reached, after which applicator assembly 43 and nozzle 51 can again rotate 90 degrees back across the width to the table, forming a second long side of box 84 opposite the first long side extending from the starting position "START." The applicator assembly 43 and nozzle 51 can then make a third 90 degree rotation to print the material while moving downward at a 45 degree angle (e.g., parallel to plane 70) to the position where the process began, as identified by "END" in FIG. 8B.

[0069] The above process can be repeated layer by layer to generate a rectangular closed shape at a 45-degree angle. Specifically, the first half of box 84 can be formed by depositing material in gradually longer rectangular layers 87, with each layer then having a smaller width and length, creating a gradually smaller rectangle to complete the part, i.e., box 84. This can result in a printed small, closed, hollow box 84, but can also be used to form different shapes and larger parts with hollow interiors (e.g., completely hollow and without any fill). While box 84 is shown with multiple rectangular layers, it will be understood that one or more layers of the part can be curved and have different shapes. As a further example, a hollow sphere can be formed by depositing material with an additive manufacturing apparatus 1 configured for tilt printing. It will be understood that tilt printing, including printing at an approximately 45-degree angle, can be used to create other closed structures, including structures without any support material and / or structures with hollow interiors, as described above.

[0070] While the principles of the present disclosure are described herein with reference to exemplary embodiments for particular applications, it should be understood that the disclosure is not limited to these embodiments. Those of ordinary skill in the art and with access to the teachings presented herein will recognize that additional modifications, applications, embodiments, and equivalent substitutions are all within the scope of the embodiments described herein. Accordingly, the embodiments described herein are illustrative and exemplary, and not limiting. [Explanation of symbols]

[0071] 1. Additive manufacturing equipment 20 beds 21 Side wall 22 Side wall 23 Printing Gantry 24 Carriage 25 Career 27 Horizontal workbench 28 Guide rail 29 Guide rail 30 Support member 31 Guide rail 32 guide rail 33 Guide rail 35 guide rail 36 Trimming Gantry 37 Vertical workbench 38 Conveyor Belt 39 Rail 40 Rail 43 Applicator assembly 48 Conveyor Belt 61 Extruder

Claims

1. 1. An additive manufacturing apparatus comprising: an extruder configured to receive the material; a work surface extending to define a plane for receiving one or more layers of said material; an applicator assembly secured to a downstream portion of the additive manufacturing device; and a nozzle coupled to the applicator assembly, the nozzle configured to receive the material from the extruder and deposit the material onto the work surface; an actuator configured to displace the work surface in a direction of movement; wherein the direction of movement forms an acute angle with the plane.

2. The additive manufacturing device of claim 1 , wherein the nozzle extends to define a longitudinal axis, the longitudinal axis forming an angle with the plane.

3. The additive manufacturing device of claim 1 , further comprising a cooling plate.

4. The additive manufacturing apparatus of claim 3 , wherein the cooling plate defines a horizontally extending surface.

5. The additive manufacturing device of claim 3 , wherein the cooling plate is actively cooled.

6. The additive manufacturing device of claim 3 , wherein the additive manufacturing device is configured to position the work surface adjacent a leading edge of the cooling plate.

7. The additive manufacturing device of claim 1 , wherein the acute angle is an angle of about 30 degrees to about 60 degrees.

8. The additive manufacturing apparatus of claim 1 , wherein the acute angle is measured upward from a direction of movement toward a top of the work surface.

9. 1. An additive manufacturing apparatus comprising: a work surface extending at an acute angle to the horizontal; an applicator assembly; a nozzle coupled to the applicator assembly, the nozzle defining a longitudinal axis extending perpendicular to the work surface; a roller configured to compress material deposited on the work surface by the nozzle; An additive manufacturing device comprising:

10. 10. The additive manufacturing apparatus of claim 9, wherein the acute angle is from about 30 degrees to about 60 degrees when measured upward toward the top of the work surface.

11. The additive manufacturing device of claim 10 , wherein the acute angle is between about 40 degrees and about 50 degrees.

12. 10. The additive manufacturing device of claim 9, wherein the additive manufacturing device comprises an actuator configured to move the work surface in a horizontal direction.

13. The additive manufacturing apparatus of claim 9 , further comprising a plate forming a surface extending in a horizontal plane.

14. 1. An additive manufacturing method comprising: receiving material in an extruder; heating the material in the extruder; depositing the heated material with a nozzle onto an inclined surface to form a first material layer, the inclined surface forming an acute angle with the horizontal; translating the ramp in a horizontal direction away from the nozzle; depositing the heated material with the nozzle onto the inclined surface to form a second material layer; A method comprising:

15. The method of claim 14 further comprising compressing the first layer of material with a compression device.

16. 15. The method of claim 14, wherein the first layer of material, the second layer of material, or both contact a cooling plate during at least a portion of the additive manufacturing method.

17. 15. The method of claim 14, wherein the first layer of material and the second layer of material together form a portion of a part, the part having a hollow interior completely enclosed by the deposited material.

18. 18. The method of claim 17, wherein the center of the hollow interior is free of deposited material.

19. The method of claim 17 , wherein the component is formed without depositing a structural support that is separated from the component.

20. The method of claim 14 , wherein the angled surface translates with the first and second layers of material.

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