System and method for dynamically controlling a multi-extruder thermoset three-dimensional printer

Abstract

A computer system for dynamically controlling printing parameters in a three dimensional printer receives an indication for printing a target object with the three dimensional printer. The computer system accesses a material attribute dataset. The material attribute dataset describes different material properties of a plurality of thermosetting materials or mixtures thereof. Based on the material attribute dataset, the computer system selects, for each of a plurality of extruders, one or more thermosetting materials of a plurality of thermosetting materials for each of the plurality of extruders to form an extrusion and determines an extrusion configuration of the selected one or more thermosetting materials. The computer system then generates commands to cause the multiple extruders of the thermosetting three dimensional printer to implement the extrusion configuration of the multiple extruders while printing the target object.

Description

[Technical field]

[0001] Government Rights This invention was made with Government support under Contract No. W911NF-17-2-0227 awarded by the US Army ACC-APG-RTP W911NF. The Government has certain rights in this invention.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 292,753, filed December 22, 2021, and entitled “SYSTEM AND METHOD FOR DYNAMICALLY CONTROLLING THERMOSET THREE-DIMENSIONAL PRINTER WITH MULTIPLE EXTRUDERS,” which is expressly incorporated herein by reference in its entirety. [Background technology]

[0003] The present invention relates to computer control of three dimensional printing methods using co-reactive materials. In particular, the present invention relates to dynamically controlling multiple extruders in a thermosetting three dimensional printer based on the different materials used by the three dimensional printer.

[0004] Three-dimensional (3D) printing, also referred to as additive manufacturing, has experienced a technological explosion in the past few years. This increased interest is related to the ability of 3D printing to easily produce a wide variety of objects from a common computer-aided design (CAD) file. In 3D printing, a composition is applied in successive layers of material to build a structure. These layers can be produced, for example, from liquid, powder, paper, or sheet materials.

[0005] In a conventional configuration, a 3D printing system utilizes a thermoplastic material. The 3D printing system extrudes the thermoplastic material through a heated nozzle onto a platform. Using instructions derived from a CAD file, the system moves the nozzle relative to the platform, successively building up layers of the thermoplastic material to form the 3D object. After being extruded from the nozzle, the thermoplastic material cools. Hence, the resulting 3D object is made of layers of thermoplastic material extruded in a heated form and layered on top of each other.

[0006] There are many ways in which 3D printing can be improved. These improvements can include faster prints, higher resolution prints, and a more durable final product, among many other desired results. Summary of the Invention

[0007] A computer system for dynamically controlling printing parameters in a three-dimensional printer includes one or more processors and one or more computer-readable media having executable instructions stored thereon, which when executed by the one or more processors configure the computer system to perform various actions. For example, the computer system receives an indication to print a target object with the three-dimensional printer. The computer system accesses a material attribute dataset. The material attribute dataset describes different material properties of a plurality of thermosetting materials or mixtures thereof. Based on the material attribute dataset, the computer system selects, for each of a plurality of extruders, one or more thermosetting materials of a plurality of thermosetting materials for each of the plurality of extruders to form an extrusion, and determines an extrusion configuration of the selected one or more thermosetting materials. The computer system then generates commands to cause the plurality of extruders of the thermosetting three-dimensional printer to implement the extrusion configuration of the plurality of extruders while printing the target object.

[0008] A three-dimensional printer (3D) may include multiple extruders, each configured to extrude a different extrudate. The 3D printer may also include one or more processors and one or more computer-readable media having executable instructions stored thereon that, when executed by the one or more processors, configure the three-dimensional printer to perform various actions. For example, the 3D printer may receive a command to print a target object. Based on the command, for each of the multiple extruders, the 3D printer may select one or more thermosetting materials from among a plurality of thermosetting materials, mix the selected one or more thermosetting materials to form an extrudate, set an extrusion configuration, and extrude the extrudate based on the extrusion configuration.

[0009] A computer-implemented method executing on more than one processor for dynamically controlling a thermosetting three dimensional printer to produce desired material attributes includes receiving an indication for printing a target object with the three dimensional printer. The method also includes accessing a material attribute dataset. The material attribute dataset describes different material properties of a plurality of thermosetting materials during printing. Based on the material attribute dataset, for each of a plurality of extruders, the method includes selecting, for each of the plurality of extruders, one or more thermosetting materials of the plurality of thermosetting materials to form an extrusion, determining an extrusion configuration of the one or more thermosetting materials, and generating commands to cause the plurality of extruders of the thermosetting three dimensional printer to implement the particular extrusion configuration while printing the target object.

[0010] Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and the appended claims, or may be learned by the practice of the exemplary implementations as set forth hereinafter.

[0011] To explain the manner in which the above-mentioned, and other advantages and features of the invention can be obtained, a more particular description of the principles briefly described above will be made by reference to specific embodiments thereof which are illustrated in the accompanying drawings, with the understanding that these drawings depict only typical embodiments of the invention and therefore should not be considered as limiting its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings which are described hereinafter. [Brief description of the drawings]

[0012] [Figure 1] 1 illustrates a system for thermosetting 3D printing. [Diagram 2] 1 illustrates a schematic diagram of a computer system for thermosetting 3D printing. [Diagram 3] Illustrates a side view of different bead sizes. [Figure 4A] Illustrates different extruder and thermoset feed configurations. [Figure 4B] Illustrates different extruder and thermoset feed configurations. [Figure 4C] Illustrates different extruder and thermoset feed configurations. [Diagram 5] 5 depicts a flow chart of a method 500 for dynamically controlling a thermoset three-dimensional printer using multiple extruders. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The present invention extends to systems, methods, and apparatus for dynamically controlling multiple extruders in a thermosetting three-dimensional (3D) printer. The systems, methods, and apparatus operate through the deposition of a co-reactive material while creating a target object. As used herein, "target object" may refer to a physical object or a portion of a complete physical object that is being additively manufactured by the systems, methods, and / or apparatus described herein. Additionally, as used herein, co-reactive material includes a thermosetting material.

[0014] Additive manufacturing using co-reactive components has several advantages over alternative additive manufacturing methods. As used herein, "additive manufacturing" refers to the use of computer-aided design (e.g., through a user-generated file or a 3D object scanner) to have an additive manufacturing device deposit material layer by layer in precise geometric shapes. Additive manufacturing using co-reactive components can create stronger parts because materials that form successive layers can be co-reacted to form covalent bonds between the layers. Also, higher filler contents can be used because the components have low viscosity when mixed. Higher filler contents can be used to modify the mechanical and / or electrical properties of the material and the target object built. Co-reactive components can extend the chemistry used in additively manufactured parts to provide improved properties such as solvent and heat resistance.

[0015] Additionally, the ability to use a computer system to control the use of co-reactive components within an additive manufacturing environment provides several advantages. For example, the computer system can dynamically control and adjust the flow rates and tool paths of the co-reactive components in a manner that produces desired physical attributes of the resulting material. Such adjustment and control provides unique advantages within additive manufacturing.

[0016] For the purposes of the following detailed description, it should be understood that the invention can take various alternative variations and sequences of steps unless expressly specified to the contrary. Moreover, other than in any operating example, or where otherwise indicated, all numbers expressing amounts of ingredients used in the specification and claims, for example, should be understood in all instances to be modified by the term "about". Thus, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations that may vary depending on the desired properties obtained by the present invention. At the very least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of at least the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0017] It is also to be understood that any numerical range recited herein is intended to include all subranges subsumed therein. For example, a range "1 to 10" is intended to have all subranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, i.e., minimum values ​​equal to or greater than 1 and maximum values ​​equal to or less than 10.

[0018] The use of the singular includes the plural and the plural encompasses the singular unless specifically stated otherwise. Additionally, although "and / or" may be expressly used in certain instances, the use of "or" means "and / or" unless specifically stated otherwise.

[0019] The term "polymer" is meant to include prepolymers, homopolymers, copolymers, and oligomers.

[0020] In addition, unless otherwise indicated, numbers expressing quantities, components, distances, or other measurements used in the specification and claims are to be understood as being modified, as appropriate, by the term "about" or its synonyms. When the terms "about," "approximately," "substantially," or the like are used in conjunction with a stated quantity, value, or condition, it may be interpreted to mean an amount, value, or condition that deviates by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01% of the stated quantity, value, or condition.

[0021] The configurations of the present disclosure are directed to the generation of structural objects using 3D printing. The 3D object may be generated by depositing at least two co-reactive components onto a substrate, followed by depositing additional portions or layers of the object on top of the portions or layers deposited below, thereby forming successive portions or layers of the object. The layers are deposited sequentially to build the 3D printed object. The co-reactive components may be mixed and then deposited, or may be deposited separately. When deposited separately, the components may be deposited simultaneously, or sequentially, or both simultaneously and sequentially.

[0022] Deposition and like terms refer to the application of a co-reactive or printing material containing a co-reactive composition and / or reactive components thereof onto a substrate (for a first portion of an object) or onto a previously deposited portion or layer of an object. Each co-reactive component may include monomers, pre-polymers, adducts, polymers, and / or cross-linkers capable of chemically reacting with the constituents of the other co-reactive components.

[0023] At least two co-reactive components can be mixed together and deposited as a mixture of co-reactive components that react to form a portion of the object. For example, two co-reactive components can be mixed together and deposited as a mixture of co-reactive components that react to form a co-reacted composition by delivering at least two separate streams of the co-reactive components into a mixing device, such as a static mixer, to generate a single stream that is then deposited. The co-reactive components can be at least partially reacted by the time the composition comprising the reaction mixture is deposited. The deposited reaction mixture can at least partially react after deposition and can also react with previously and / or subsequently deposited portions of the object, such as an underlying or overlying layer of the object.

[0024] Alternatively, the two coreactive components may be deposited separately from one another and react upon deposition to form a portion of the object. For example, the two coreactive components may be deposited separately, such as using an inkjet printing system, whereby the coreactive components are deposited overlapping and / or adjacent to one another in sufficient proximity such that the two reactive components may react to form a portion of the object. As another example, in an extrudate, rather than being homogenous, the cross-sectional profile of the extrudate may be heterogeneous such that different portions of the cross-sectional profile may have one of the two coreactive components and / or may contain a mixture of the two coreactive components in different molar and / or equivalence ratios.

[0025] Additionally, different portions of the object may be formed using different ratios of the two co-reactive components such that different portions of the object may be characterized by different material properties throughout the 3D printed object. For example, some portions of the object may be rigid and other portions of the object may be flexible. As used herein, "material properties" refers to the physical material properties of a cured and / or uncured thermosetting material. For example, material properties may refer to the viscosity of an uncured thermosetting material. In other examples, material properties may refer to the stiffness of a cured thermosetting material after it has been extruded to create a desired target object. Thus, material properties refer to the physical material properties of a co-reactive material at various different stages.

[0026] It will be understood that the viscosity, reaction rate, and other properties of the co-reactive component can be adjusted to control the flow of the co-reactive component and / or the co-reactant composition such that the deposited portion and / or object achieves and retains the desired structural integrity after deposition. The viscosity of the co-reactive component can be adjusted by including a solvent, or the co-reactive component can be substantially free of solvent or completely free of solvent. The viscosity of the co-reactive component can be adjusted by including a filler, or the co-reactive component can be substantially free of filler or completely free of filler. The viscosity of the co-reactive component can be adjusted by using components with lower or higher molecular weights. For example, the co-reactive component can include a prepolymer, a monomer, or a combination of a prepolymer and a monomer. The viscosity of the co-reactive component can be adjusted by changing the deposition temperature. The co-reactive component can have a viscosity and temperature profile that can be adjusted for the particular deposition method used, such as mixing before deposition and / or inkjet. Viscosity can be influenced by the composition of the co-reactive component itself and / or can be controlled by the inclusion of a rheology modifier as described herein.

[0027] It may be desirable for the viscosity and / or reaction rate to be such that the composition retains its intended shape after deposition of the coreactive component. For example, if the viscosity is too low and / or the reaction rate is too slow, the deposited composition may flow in a manner that compromises the desired shape of the finished object. Similarly, if the viscosity is too high and / or the reaction rate is too fast, the desired shape may be compromised.

[0028] Referring now to the figures, FIG. 1 illustrates a system for 3D printing using co-reactive components. The depicted system comprises a 3D printer 100 in communication with a computer system 110. Although depicted as a physically separate component, the computer system 110 may also be fully integrated within the 3D printer 100, distributed among multiple different electronic devices (including cloud computing environments), or otherwise integrated with the 3D printer 100. As used herein, a "3D printer" refers to any device that enables additive manufacturing using computer-generated data files. Such computer-generated data files herein are referred to as "CAD files."

[0029] The depicted 3D printer 100 is depicted with a target object 120 in the form of a wedge shape. The wedge shape is constructed by the 3D printer 100, at least in part, using a co-reactive component. The 3D printer 100 also includes a dispenser 130 attached to a movement mechanism 140. As used herein, a "dispenser" may include one or more extruders, one or more dynamic nozzles, one or more static nozzles, one or more jetting devices, one or more injection devices, one or more dispensing devices, one or more spraying devices, or any other device capable of providing a controlled flow of the co-reactive component.

[0030] Additionally, the movement mechanism 140 is depicted as comprising a dispenser mounted in tracks 142 that are movable along the arm in an X-axis direction, and another set of tracks 144 along which the arm is movable in a Y-axis direction. However, it should be understood that this configuration is provided for purposes of example and explanation only. In additional or alternative configurations, the movement mechanism 140 may comprise any system capable of controlling the position of the dispenser 130 relative to the target object 120, including, but not limited to, a system that moves the target object 120 relative to the dispenser 130.

[0031] Additionally, the 3D printer 100 is connected to one or more containers 152(a-e) of co-reactive components. In the depicted embodiment, the co-reactive components are accessed through a selectable manifold 150 that allows a user to select a desired container 152(a-e) from which to draw the co-reactive components. However, it will be understood that the depicted system for 3D printing is merely exemplary. For example, in alternative cases, the system may include a different configuration of co-reactive components and selectable manifold 150, or may not include a selectable manifold 150 at all.

[0032] 2 illustrates a schematic diagram of a computer system for thermoset 3D printing. Computer system 110 is shown in communication with 3D printer 100. Additionally, various modules, or units, of 3D printing design software 200 are depicted as being executed by computer system 110. In particular, 3D printing design software 200 is depicted as comprising a tool path generation unit 240, a flow processing unit 242, a dispenser control unit 244, and a material database 246 (also referred to herein as a "material attribute database" and a "material attribute data set").

[0033] The depicted computer system for thermoset 3D printing is further shown as including a first co-reactive component container 250a and a second co-reactive component container 250b that are provided directly to the 3D printer 100. Thus, the 3D printer 100 can extract co-reactive components from the first co-reactive component container 150a and the second co-reactive component container 150b as desired. However, it will be understood that this configuration is merely exemplary and that additional or alternative configurations may utilize different configurations of co-reactive component containers to provide co-reactive components to the 3D printer 100.

[0034] As used herein, a "module" includes computer executable code and / or computer hardware that performs a particular function. Those skilled in the art will appreciate that the distinction between different modules is at least partially arbitrary, and that modules may be otherwise combined and divided and still be within the scope of the present disclosure. Thus, the description of components as being "modules" is provided for clarity and explanation only, and should not be construed as indicating that any particular structure of computer executable code and / or computer hardware is required unless otherwise expressly stated. In this description, terms such as "unit," "component," "agent," "manager," "service," "engine," "virtual machine," and the like may be used as well.

[0035] The computer system 110 also includes one or more processors 210 and one or more computer storage media 220 having executable instructions stored thereon that, when executed by the one or more processors 210, configure the computer system 110 to perform various acts. For example, the computer system 110 may receive an indication to cause the 3D printer 100 to print a layer. As used herein, an "indication" includes any form of input received by the computer system 110. For example, an indication may include a manual input by a user, an automated action performed by the computer system 110 or another remote computer system, the execution of a software application, the selection of a user interface element in a graphical user interface, the receipt of a data file, or any other form of input that causes the computer system 110 to perform further actions.

[0036] When an indication to print a layer of the target object 120 is received by the computer system 110, the tool path generation unit 240 generates a tool path for additively manufacturing the target object 120. As used herein, "tool path" refers to a path of the dispenser 130 in manufacturing the target object 120. Additionally, "tool path" may also refer to a speed and / or flow rate of the dispenser 130 in manufacturing the target object 120. The tool path generation unit 240 generates the tool path such that the co-reactive material is dispensed from the dispenser 130 at a speed and along a path that creates the target object 120.

[0037] In some circumstances, the tool path may require the dispenser 130 to layer the co-reactive materials on themselves in layers. The flow rate processing unit 242 calculates a target rate to ensure that the co-reactive materials bond properly between different layers. Such calculations may account for the reaction time of the co-reactive materials, such as layering layers on top of each other before the lower layer is fully cured. In this manner, the generation of the first tool path may be based, at least in part, on the target flow rate. As discussed above, such information regarding the amount of time that different co-reactive components remain reactive is provided by the material database 246. The material database 246 may include information about the material attributes of the co-reactive materials in both the cured and uncured states.

[0038] As used herein, a "flow rate" includes a rate at which one or more components of a material are dispensed from a dispenser 130. The flow rate may be controllable for each component. For example, the tool path generation unit 240 includes a flow rate processing unit 242 that determines and controls a target flow rate for dispensing a co-reactive material to create the target object 120.

[0039] The flow rate processing unit 242 may be configured to manipulate the flow rate of the co-reactive material by modifying the properties of the co-reactive components within the co-reactive material while creating the target object 120. It will be appreciated that the viscosity, reaction rate, and other properties of the co-reactive components may be adjusted to control the flow of the co-reactive components and / or the thermosetting composition such that the deposited part and / or object achieves and retains the desired structural integrity after deposition. The viscosity of the co-reactive components may be adjusted by including a solvent, or the co-reactive components may be substantially free of solvent or completely free of solvent. The viscosity of the co-reactive components may be adjusted by including a filler, or the co-reactive components may be substantially free of filler or completely free of filler. The viscosity of the co-reactive components may be adjusted by using components with lower or higher molecular weights. For example, the co-reactive components may include prepolymers, monomers, or a combination of prepolymers and monomers. The viscosity of the co-reactive components may be adjusted by modifying the deposition temperature. The co-reactive components may have viscosity and temperature profiles that may be tailored to the particular deposition method used, such as pre-deposition and / or pre-ink-jetting. Viscosity may be influenced by the composition of the co-reactive components themselves and / or controlled by the inclusion of rheology modifiers as described herein.

[0040] It may be desirable for the viscosity and / or reaction rate to be such that the composition retains its intended shape after deposition of the coreactive component. For example, if the viscosity is too low and / or the reaction rate is too slow, the deposited composition may flow in a manner that compromises the desired shape of the finished object. Similarly, if the viscosity is too high and / or the reaction rate is too fast, the desired shape may be compromised.

[0041] For example, the co-reactive components that are deposited together may each have a viscosity at 25° C. and a 0.1 s viscosity of 5,000 centipoise (cP) to 5,000,000 cP, 50,000 cP to 4,000,000 cP, or 200,000 cP to 2,000,000 cP. -1The co-reactive components that are deposited together can each have a viscosity at 25° C. and a shear rate of 1,000 s of 50 centipoise (cP) to 50,000 cP, 100 cP to 20,000 cP, or 200 to 10,000 cP. -1 The viscosity values ​​can be measured using an Anton Paar MCR301 or 302 rheometer with a gap of 1 mm to 2 mm.

[0042] Additionally, the viscosity and / or reaction rate can be adjusted to control the actual bead size or layer size dispensed by the dispenser 130. As used herein, "bead" includes a layer of material dispensed by the dispenser 130 on the tool path. Similarly, as used herein, "bead size" includes one or more dimensions of a layer being dispensed by the dispenser 130. For example, the bead size may include the height of the bead, the radius of the bead, the width of the bead, or any other physical dimension of the bead. Although the word "bead" is used herein, it will be understood that the actual layer need not physically resemble a conventional bead shape.

[0043] Additionally or alternatively, the dispenser control unit 244 may adjust the properties of the 3D printer 100 to achieve the desired flow rate. For example, the dispenser control unit 244 may move the dispenser 130 faster or slower to achieve the desired bead size, deposition rate, viscosity, and / or reaction rate. For example, if the dispenser 130 is dispensing the co-reactive material at a constant speed and the dispenser control unit 244 moves the dispenser at a faster speed during deposition, the resulting bead size will be smaller. Similarly, the dispenser control unit 244 may cause the dispenser 130 to dispense the co-reactive material at a higher or lower speed based on the desired flow rate and / or bead size. In this manner, the flow rate processing unit 242 may adjust the properties of the co-reactive components in the material and / or the dispenser control unit 244 may adjust the mechanical operation of the 3D printer 100 to achieve the desired flow rate and / or bead size.

[0044] In some configurations, the 3D printer 100 may be capable of utilizing multiple different types of materials to manufacture the target object 120. These different materials may include different combinations of co-reactive components. For example, FIG. 1 depicts one or more containers 152(a-e) of co-reactive components, each of which may include a different type of co-reactive component. Upon receiving the indication of the material, the tool path generation unit 240 accesses the properties of the material from the material database 246. In some cases, the indication of the material includes a particular mixture of co-reactive components, such as a particular mixture of co-reactive components provided by one or more containers 152(a-e) of co-reactive components. The properties of the material include the viscosity of the material and / or various other attributes related to the reactivity of the material. Using information from the material database 246 and the process described above, the tool path generation unit 240 uses the properties of the material to determine the target flow rate and / or bead size.

[0045] Additionally, in some configurations, the co-reactive components may utilize an external stimulus, such as UV light, during the reaction process. In such cases, the 3D printer 100 may include a UV light source that is controllable by the computer system 110. The 3D printer 100 may be configurable to dispense the co-reactive material and cure the material with the UV light source. Various other stimuli may be similarly implemented by the computer system 110 such that the stimulus is applied to the co-reactive material during and / or after dispensing of the co-reactive material.

[0046] Returning to controlling the thermosetting 3D printer 100 to create desired material attributes, the 3D printing design software 200 can calculate a specific mixture composition of one or more thermosetting materials to achieve the desired final material properties of the surface. Conventional 3D printers usually have a single extruder that is configured to print a 3D object using a single material, and conventional 3D printing software is designed to print a 3D object using a single extruder. Unlike conventional 3D printers, the 3D printer 100 described herein may include two or more extruders. Each of the extruders is configured to extrude a different material, which may be a specific thermosetting material or a combination of multiple different thermosetting materials. In some cases, the multiple extruders are configured to extrude beads formed by different materials substantially simultaneously and at substantially the same location, such that the multiple beads (formed by the different materials) react or partially react with each other to form a single bead of reactive material. In some cases, the later extruded material is configured to form a coating that covers the portion formed by the previously extruded material.

[0047] Depending on the mixture configurations of the different thermosetting materials used, the 3D printer 100 is configured to print target objects having different final material properties and / or surface material properties. Furthermore, a user can simply input the desired final material properties of the surface of the target object to be printed. In response to the user's input, the computer system 110 is configured to determine a particular mixture configuration of one or more thermosetting materials to achieve the desired final material properties of the surface.

[0048] For example, computer system 110 is configured based on indications received from a user (directly or indirectly from the user, another computer program, and / or 3D printer 100). The indications include indications of desired final material properties of the surface of the target object to be printed. In some configurations, the indications may be input directly by a user at computer system 110 or at 3D printer 100. In some configurations, the indications may be configured within a thermoset print data packet, which may be generated by 3D printing software 220 based on the user's indications. In some configurations, the desired final material properties may include tensile properties, hardness properties, wear resistance properties, and / or smoothness properties.

[0049] The computer system 110 is also configured to receive an indication of one or more thermosetting materials (contained in the containers 152a-152e) available to the thermosetting three-dimensional printer. The indication may also be received directly or indirectly from a user, another computer program, a barcode on the containers 152a-152e, an integrated circuit in the containers 152a-152e, and / or the 3D printer 100. In response to the indication of the desired final material properties of the surface of the target object and the indication of the one or more thermosetting materials, the 3D printing design software 200 accesses a material attribute data set stored in the material attribute database 246. The material attribute data set describes different material properties resulting based on different mixture configurations of the one or more thermosetting materials. Based on the information in the material attribute database 246, the 3D printing design software 200 determines a particular mixture of one or more thermosetting materials to achieve the desired final material properties of the surface, and generates commands that cause the thermosetting 3D printer 100 to implement the particular mixture of one or more thermosetting materials when printing the surface.

[0050] In some configurations, a particular mixture configuration includes a particular ratio of one or more thermosetting materials. For example, a first extruder may be configured to extrude beads formed by a first material, and a second extruder may be configured to extrude beads formed by a second material. Based on the particular ratio determined by the 3D printing design software 200, the first extruder may be configured to extrude beads having a first size, and the second extruder may be configured to extrude beads having a second size.

[0051] For example, Figure 3 illustrates a side view of different bead sizes. In the depicted example, the first bead size 310 is largest, the second bead size 320 is smaller than the first bead size 310, the third bead size 330 is smaller than the second bead size 320, etc. Based on the determined ratio of the one or more thermosetting materials and / or the desired final material properties (e.g., desired smoothness properties), the 3D printing design software 200 may determine that the first bead size 310 is implemented for the first thermosetting material and the second bead size 320 is implemented for the second thermosetting material among the one or more thermosetting materials.

[0052] 4A-4C depict schematic diagrams of a 3D printer 100 with multiple extruders 450(a,b,c) and 460(a,b,c). In the depicted embodiment, the multiple extruders 450(a,b,c), 460(a,b,c) and nozzles are shown as single elements. Thus, references to the multiple extruders 450(a,b,c), 460(a,b,c) also include the associated nozzles. However, as discussed in more detail below, the nozzles may be interchangeable such that each of the multiple extruders 450(a,b,c) and 460(a,b,c) is associated with a separate nozzle that may include specific properties related to the extrusion of thermosetting materials. In some configurations, the 3D printer 100 may be configured such that each of the multiple extruders 450(a,b,c) and 460(a,b,c) extrudes a different extrusion. Additionally or alternatively, the 3D printer 100 can be configured such that at least a portion of the multiple extruders 450(a,b,c) and 460(a,b,c) extrude the same extrudate.

[0053] The computer system 110 may receive indications for printing the target object 120 with the 3D printer 100. In Figures 4A-4C, the target object includes tool paths 472(a,b,c), 474(a,b,c), 476(a,b,c), and 478(a,b,c). The different tool paths 472(a,b,c), 474(a,b,c), 476(a,b,c), and 478(a,b,c) are extruded by multiple extruders 450(a,b) and 460(a,b) such that multiple different extruders are used to create the target object 120.

[0054] When the computer system 110 receives the indications for printing the target object 120, the indications may include a digital file describing the physical geometry of the target object, including its dimensions. As discussed above, the digital file may further indicate the desired final material properties of the surface of the printed target object. In response, the computer system 110 may access the material attribute dataset 246. As used herein, a "material attribute dataset" includes information about the different material properties resulting from mixing various thermosetting materials, particularly the different thermosetting materials at different ratios and speeds. For example, the different material properties may include at least the flowable or gel properties of the multiple thermosetting materials, or mixtures thereof, in different ratios before co-reaction. The different material properties may additionally or alternatively include at least the hardness, flexibility, tensile strength, color, temperature resistance, sound deadening, expansion, flame retardancy, shatter resistance, expansion, electrical conductivity of the multiple thermosetting materials, or mixtures thereof, in different ratios after co-reaction.

[0055] In some cases, the indications for printing the target object 120 may not include any specified desired final material properties, but instead, the computer system 110 may automatically calculate one or more desired final material properties based on the physical geometry of the target object 120. For example, the computer system 110 may identify an overhang within the physical geometry of the target object 120. In response to identifying the overhang, the computer system may automatically calculate that one or more surfaces of the target object 120 must have a certain level of rigidity to support the overhang. The determination of the rigidity may be made by accessing a lookup table within the material attribute database 246 and may also depend on the type of thermosetting material used to create the overhang. For example, the material attribute database 246 may provide a lookup table or formula for calculating the amount of rigidity and structural support provided by a given material within the available thermosetting materials. Using this information, the computer system 110 generates the desired final material properties of the surfaces of the target object 120 required to maintain the desired overhang. It will be understood that the above description relating to overhand is merely exemplary, and that the same look-up tables and calculations of desired final material properties can be calculated by computer system 110 in response to a variety of different physical geometries.

[0056] Based on the material attribute data set, for each of the plurality of extruders 450(a,b) and 460(a,b), the computer system 110 selects one or more of the plurality of thermosetting materials (e.g., one or more of the reservoirs 152(a-e)) for each of the plurality of extruders to form an extrusion. Additionally, for each of the plurality of extruders 450(a,b) and 460(a,b), the 3D printer 100 determines an extrusion configuration of the selected one or more of the thermosetting materials. The act of selecting one or more of the thermosetting materials for each of the plurality of extruders 450(a,b) and 460(a,b) may comprise the computer system 110 communicating commands to the manifold 150 to open and close specific channels between the one or more of the reservoirs 152(a-e) and each of the plurality of extruders 450(a,b) and 460(a,b). For example, in FIG. 4A, extruder 450a is fed by sources 410a and 420a, while extruder 460a is fed by sources 430a and 440a. In contrast, in FIG. 4B, extruder 450b is fed by sources 410b and 420b, while extruder 460b is also fed by source 420b and separately fed by source 430b. As used herein, "source" refers to vessels 152(a-e) and vessels 250(a,b). Thus, in some configurations, each of the multiple extruders is coupled to a separate set of material sources 410A and 420A, or 430A and 440A. Alternatively, in some configurations, each of the multiple extruders is coupled to the same set of material sources 410C, 420C, 430C.

[0057] As used herein, "extrusion configuration" refers to variables applied to the extrusion of material from a 3D printer. For example, the act of determining the extrusion configuration of each of the plurality of extruders 450(a,b) and 460(a,b) may include determining at least one of the thermosetting material to extrude, the extrusion speed, the extrusion timing, or the extrusion path. Additionally or alternatively, determining the extrusion configuration of each of the plurality of extruders 450(a,b) and 460(a,b) may include selecting a particular nozzle to be paired with a particular extruder of the plurality of extruders 450(a,b) and 460(a,b) or adjusting a dynamic nozzle associated with a particular extruder of the plurality of extruders 450(a,b) and 460(a,b). For example, the plurality of extruders 450(a,b) and 460(a,b) may include a first extruder 450a having a first set of extrusion properties and a second extruder 460a having a second set of extrusion properties. The extrusion properties include the orifice dimensions of the extruder, the material composition of the extruder, the maximum and minimum extrusion rates of the extruder, the nozzle(s) associated with the extruder, and various other similar properties. The computer system 110 may further determine the extrusion configuration of each of the multiple extruders by configuring a first extruder to extrude a material having a first set of material properties and configuring a second extruder to extrude a material having a second set of material properties. Thus, the computer system 110 may cause an extruder with a larger orifice to extrude a thermosetting material that benefits from a larger output volume. It will be appreciated that more than two materials may actually be utilized by one or more than one extruder. Additionally, any number of different extruders may extrude any number of different materials having any number of different material attributes.

[0058] The computer system 110 communicates commands that are received by the 3D printer 100 to print the target object 120. In particular, the computer system 110 may generate commands that cause the multiple extruders 450(a,b) and 460(a,b) of the thermosetting 3D printer 100 to implement extrusion configurations while printing the target object 120. In the depicted example, the target object 120 has multiple portions (indicated by tool paths 472(a,b,c), 474(a,b,c), 476(a,b,c), and 478(a,b,c)) having different material properties. The computer system 110 selects, for each of the multiple portions, one or more thermosetting materials from among the multiple thermosetting materials to form an extrusion, selects one of the multiple extruders, and determines a specific extrusion configuration for the selected extruder and the extrusion.

[0059] In some configurations, the 3D printer 100 mixes the thermosetting materials in a particular order to form the extrudate. Additionally or alternatively, in some configurations, another device mixes the thermosetting materials to form the extrudate. The 3D printer 100 then sets the extrusion configuration and extrudes the extrudate based on the extrusion configuration.

[0060] For example, in FIG. 4A, extruder 450a extrudes along tool path 472a, and then extruder 460a extrudes along the immediately adjacent tool path 474a. In at least one embodiment, the two extruders 450a and 460a extrude simultaneously such that the two tool paths 472a, 474a are extruded simultaneously. Additionally or alternatively, extruders 450a, 460a may extrude tool paths 476a and 478a sequentially. Tool path generation unit 240 may utilize material attribute database 246 in calculating whether the tool paths should be extruded sequentially, simultaneously, or some mixture thereof. For example, tool path generation unit 240 may factor in the cure time of the selected thermosetting material to ensure that tool paths 472(a,b,c), 474(a,b,c), 476(a,b,c), and 478(a,b,c) are properly bonded together. For example, relatively fast hardening materials may need to be extruded simultaneously to ensure that proper bonds occur between the various tool paths 472(a,b,c), 474(a,b,c), 476(a,b,c), and 478(a,b,c).

[0061] Additionally, the flow processing unit 242 may determine a volumetric mix ratio of the selected one or more thermosetting materials for each of the multiple portions represented by the tool paths 472(a,b,c), 474(a,b,c), 476(a,b,c), and 478(a,b,c). The computer system 110 then generates commands to cause the selected extruder to deliver the selected one or more thermosetting materials at the determined volumetric mix ratio.

[0062] In some configurations, an extruder (e.g., 450a, 450b, 450c, 460a, 460b, 460c) may utilize a purge step when switching to a new material, when finishing a tool path, and / or when beginning a tool path. For example, when a particular extruder (e.g., 450a) is switching to a new material, it may first purge the previous material that may still be contained within the extruder 450a. For example, the material database 246 may include a purge entry for each material that indicates how much extrusion is required to purge a particular material from the extruder. Thus, when switching to a new material, the computer system 100 may access the material database 246 and determine the amount of extrusion required to purge the original material from the extruder 450a. The extruder 450a may then physically move to a purge area (e.g., an area that does not cover or is not immediately adjacent to the target object 120) and extrude the amount of material indicated by the material database 246. Extruder 450a is then primed to extrude new material without contamination from the previous material.

[0063] Alternatively, in some configurations, purging the extruder 450a may include physically removing the extruder 450a from the 3D printer 100 and replacing it with another extruder. For example, in some configurations, a particular material may harden within the extruder such that the extruder 450a is unable to extrude any additional material. In some cases, it may be necessary to purge or replace the extruder even to continue extruding the same previous material. Similar to the above, the material database 246 may include information indicating whether a particular material requires a new extruder after it has been used. For example, the material database 246 may indicate how quickly a material hardens. For example, if the extruder 450 is idle for more than the hardening time indicated in the material database 246, the computer system 110 identifies that a new extruder is needed.

[0064] The computer system 110 may also be configured to continuously track the relative location of each of the extruders (e.g., 450a, 450b, 450c, 460a, 460b, 460c) with respect to one another. For example, the computer system 110 may track the locations of the extruders 450a and 450b as the target object 120 is being printed. In some cases, only a single extruder is used to extrude material at a time. Thus, when the second extruder 460a is needed to extrude material, the computer system 110 can quickly calculate an offset between the current locations of the first extruder 450a and the second extruder 460a. This offset is then used to position the second extruder 460a to properly position the second extruder 460a to continue printing the target object 120.

[0065] 5 depicts a flow chart of a method 500 for dynamically controlling a thermosetting three-dimensional printer using multiple extruders. The method 500 includes a step 510 of receiving an indication of a target object 512. Step 510 may include receiving an indication for printing the target object by the three-dimensional printer. For example, the computer system 110 receives instructions to generate the target object 120, as described and illustrated with respect to FIGS. 1 and 2.

[0066] Additionally, method 500 includes an act 520 of accessing a material attribute dataset 520. Act 520 may include accessing a material attribute dataset, where the material attribute dataset describes different material properties of a plurality of thermosetting materials or mixtures thereof. As used herein, the material attribute dataset is also referred to as material attribute database 246. For example, as discussed with respect to Figures 1 and 2, computer system 110 accesses material attribute database 246 to access information about a variety of different available thermosetting materials.

[0067] Method 500 also includes an act of selecting 532 one or more thermoset materials and an act of determining an extrusion configuration 534. Acts 532 and 534 may also include selecting one or more of the plurality of thermoset materials for each of the plurality of extruders to form an extrudate based on the material attribute dataset and determining an extrusion configuration of the selected one or more thermoset materials for each of the plurality of extruders. For example, as described with respect to Figures 4A-4C, computer system 110 may select from a variety of different thermoset materials (shown as sources 410(a-c), 420(a-c), 430(a-c), and 440(a-c)) based on the final desired material properties.

[0068] Further, the method 500 includes an act 540 of generating commands to cause multiple extruders of the thermosetting three-dimensional printer to implement multiple mixture configurations. Act 530 may include generating commands to cause multiple extruders of the thermosetting three-dimensional printer to implement extrusion configurations of the multiple extruders while printing the target object. For example, as shown in FIGS. 1-4C, the 3D printer 100 may print the target object 120 in response to commands from the computer system 110.

[0069] Although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the described features or acts or to the order of acts described above. Rather, the described features and acts are disclosed as exemplary forms of implementing the claims.

[0070] The present invention may comprise or utilize a dedicated or general-purpose computer system, including computer hardware such as, for example, one or more processors and system memory, as discussed in more detail below. Embodiments within the scope of the present invention also include physical and other computer-readable media for carrying or storing computer-executable instructions and / or data structures. Such computer-readable media may be any available media that is accessible by a general-purpose or special-purpose computer system. Computer-readable media that store computer-executable instructions and / or data structures are computer storage media. Computer-readable media that carry computer-executable instructions and / or data structures are transmission media. Thus, by way of example and not limitation, embodiments of the present invention may comprise at least two distinctly different kinds of computer-readable media: computer storage media and transmission media.

[0071] A computer storage medium is a physical storage medium that stores computer-executable instructions and / or data structures. Physical storage medium includes computer hardware such as RAM, ROM, EEPROM, solid-state drive ("SSD"), flash memory, phase-change memory ("PCM"), optical disk storage, magnetic disk storage or other magnetic storage devices, or any other hardware storage device(s) that can be used to store program code in the form of computer-executable instructions or data structures that can be accessed and executed by a general-purpose or special-purpose computer system to implement the disclosed functions of the present invention.

[0072] A transmission medium may be used to carry program code in the form of computer-executable instructions or data structures and may include a network and / or data links that may be accessed by a general-purpose or special-purpose computer system. A "network" is defined as one or more data links that enable the porting of electronic data between computer systems and / or modules and / or other electronic devices. When information is transferred or provided to a computer system over a network or another communications connection (either wired, wireless, or a combination of wired or wireless), the computer system may view the connection as a transmission medium. Combinations of the above should also be included within the scope of computer-readable media.

[0073] Furthermore, upon reaching the various computer system components, program code in the form of computer-executable instructions or data structures may be automatically transferred from a transmission medium to a computer storage medium (or vice versa). For example, computer-executable instructions or data structures received over a network or data link may be buffered in RAM in a network interface module (e.g., a "NIC") and then eventually transferred to the computer system's RAM and / or to a less volatile computer storage medium in the computer system. Thus, it should be understood that computer storage media may be included in computer system components that also (or primarily) utilize a transmission medium.

[0074] Computer-executable instructions comprise, for example, instructions and data that, when executed on one or more processors, cause a general-purpose computer system, special-purpose computer system, or special-purpose processing device to perform a certain function or group of functions. Computer-executable instructions may be, for example, binaries, intermediate format instructions such as assembly language, or source code.

[0075] Those skilled in the art will appreciate that the present invention may be practiced in a network computing environment having many types of computer system configurations, including personal computers, desktop computers, laptop computers, message processors, handheld devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, mobile phones, PDAs, tablets, pagers, routers, switches, and the like. The present invention may also be practiced in a distributed system environment in which both local and remote computer systems linked through a network (by hardwired data links, wireless data links, or by a combination of hardwired and wireless data links) perform tasks. Thus, in a distributed system environment, a computer system may include multiple constituent computer systems. In a distributed system environment, program modules may be located in both local and remote memory storage devices.

[0076] Those skilled in the art will also appreciate that the present invention may be practiced in a cloud computing environment. A cloud computing environment may be distributed, but this is not required. When distributed, a cloud computing environment may be distributed internationally within an organization and / or may have components owned across multiple organizations. In this specification and in the claims that follow, "cloud computing" is defined as a model for enabling on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, and services). The definition of "cloud computing" is not limited to any of the numerous other benefits that can be obtained from such a model when properly deployed.

[0077] The cloud computing model may consist of various characteristics such as on-demand self-service, pervasive network access, resource pooling, rapid elasticity, measured service, etc. The cloud computing model may also come in the form of various service models such as, for example, Software as a Service ("SaaS"), Platform as a Service ("PaaS"), and Infrastructure as a Service ("IaaS"). The cloud computing model may also be deployed using different deployment models such as private cloud, community cloud, public cloud, hybrid cloud, etc.

[0078] Some embodiments, such as a cloud computing environment, may comprise a system including one or more hosts, each capable of running one or more virtual machines. In operation, the virtual machines emulate an operating computing system that supports an operating system and possibly one or more other applications as well. In some embodiments, each host includes a hypervisor that emulates the virtual machine's virtual resources using physical resources abstracted from the virtual machine's view. The hypervisor also provides proper isolation between the virtual machines. Thus, from the perspective of any given virtual machine, the hypervisor provides the illusion that the virtual machine is interfacing with physical resources, even though the virtual machine only interfaces with the appearance of physical resources (e.g., virtual resources). Examples of physical resources include processing power, memory, disk space, network bandwidth, media drives, etc.

[0079] The present invention is further illustrated by the following embodiments.

[0080] In a first aspect, a computer system for dynamically controlling printing parameters in a three dimensional printer having multiple extruders is provided, preferably using the three dimensional printer according to any one of aspects 18-23, the computer system comprising one or more processors and one or more computer readable media having executable instructions stored thereon, the executable instructions, when executed by the one or more processors, preferably configure the computer system to perform a method according to aspect 24 or 25 by at least: receiving an indication to print a target object with the three dimensional printer; accessing a material attribute dataset, the material attribute dataset describing different material properties of a plurality of thermosetting materials or mixtures thereof; selecting, for each of the plurality of extruders based on the material attribute dataset, one or more thermosetting materials from among a plurality of thermosetting materials for forming an extrusion body; determining an extrusion configuration of the selected one or more thermosetting materials; and generating commands to cause the plurality of extruders of the three dimensional printer to implement the extrusion configuration of the plurality of extruders while printing the target object.

[0081] Example 2 relates to the computer system according to example 1, wherein the plurality of extruders includes a first extruder having a first set of extrusion properties and a second extruder having a second set of extrusion properties, and determining an extrusion configuration for each of the plurality of extruders includes configuring the first extruder to extrude a material having the first set of material properties and configuring the second extruder to extrude a material having the second set of material properties, preferably the first set of material properties being different from the second set of material properties.

[0082] Example 3 relates to the computer system of example 1 or 2, wherein the target object has a plurality of portions having different material properties, and for each of the plurality of portions, the computer system is further configured to: select one or more thermosetting materials from among a plurality of thermosetting materials to form an extrusion; select one of a plurality of extruders; and determine a particular extrusion configuration for the selected extruder and the extrusion.

[0083] Aspect 4 relates to the computer system of aspect 3, wherein for each of the plurality of portions, the computer system is further configured to determine a volumetric mix ratio of the one or more selected thermosetting materials, and the command is configured to cause the selected extruder to deliver the one or more selected thermosetting materials at the determined volumetric mix ratio.

[0084] Example 5 relates to any one of the computer systems of Examples 1-4, wherein the different material properties include at least flowable or gel properties of multiple thermosetting materials, or mixtures thereof, in different ratios prior to co-reaction.

[0085] Example 6 relates to any one of the computer systems of Examples 1-5, wherein the different material properties include at least hardness, flexibility, tensile strength, color, temperature resistance, sound deadening, expansion, flame retardancy, shatter resistance, expandability, electrical conductivity of the multiple thermoset materials in different ratios after co-reaction, or mixtures thereof.

[0086] Example 7 relates to any one of the computer systems described in Examples 1-6, wherein, for each of the plurality of extruders, the extrusion configuration includes at least one of an extrusion speed, an extrusion timing, or an extrusion path.

[0087] Example 8 relates to any one of the computer systems of Examples 1-7, wherein multiple extruders are used in series to create a single tool path.

[0088] Example 9 relates to any one of the computer systems of Examples 1-8, wherein each of the plurality of extruders is coupled to a separate set of material sources.

[0089] Example 10 relates to any one of the computer systems of Examples 1-9, further including: calculating an offset between a first extruder selected from the plurality of extruders and a second extruder selected from the plurality of extruders; receiving a command to switch extrusion from the first extruder to the second extruder; and utilizing the offset to position the second extruder at a location relative to the first extruder prior to extruding material from the second extruder.

[0090] Example 11 relates to any one of the computer systems of Examples 1-10, further including receiving a command to switch extrusion of the first material from the first extruder to a second material; retrieving a purge entry from the material database, the purge entry indicating an amount of extrusion and an extrusion configuration needed to purge the first material from the first extruder; positioning the first extruder in a purge zone; and purging the amount of extrusion needed to purge the first material from the first extruder.

[0091] Example 12 relates to any one of the computer systems described in Examples 1-11, wherein the material attribute dataset includes information about different material properties before co-reaction resulting from mixing various thermosetting materials in different ratios and rates, and in particular, the different material properties include at least flowable or gel properties of the multiple thermosetting materials, or mixtures thereof, in different ratios before co-reaction.

[0092] A fourteenth embodiment relates to any one of the computer systems according to the first to thirteenth embodiments, wherein the computer system comprises two to five extruders, preferably two to four extruders, and more preferably three to four extruders.

[0093] Example 15 relates to any one of the computer systems described in Examples 2-14, wherein the extrusion properties include an orifice dimension of the extruder, a material composition of the extruder, a maximum and minimum extrusion rate of the extruder, and / or a nozzle(s) associated with the extruder, and preferably, the first set of extrusion properties is different from the second set of extrusion properties.

[0094] Example 16 relates to the computer system of example 3, wherein the selection of the one or more thermosetting materials and one of the plurality of extruders is based on different material properties of the respective portions of the target object, taking into account in particular the different material properties of the one or more thermosetting materials.

[0095] Example 17 relates to the computer system of any one of Examples 1-16, wherein each extruder utilizes a different thermosetting material or a mixture of thermosetting materials, in particular to dynamically control different material properties of different portions of the target object.

[0096] In an eighteenth aspect, a three dimensional printer is provided, preferably present in a computer system according to any one of aspects 1-17, comprising a plurality of extruders, each configured to extrude a different extruded body, one or more processors, and one or more computer readable media having executable instructions stored thereon, wherein the executable instructions, when executed by the one or more processors, configure the three dimensional printer, preferably using a method according to aspect 24 or 25, to at least: receive a command to print a target object; select, for each of the plurality of extruders, one or more thermosetting materials from among a plurality of thermosetting materials based on the command; mix the selected one or more thermosetting materials to form an extruded body; set an extrusion configuration; and extrude the extruded body based on the extrusion configuration.

[0097] Example 19 relates to the three dimensional printer of example 18, wherein the command to print the target object indicates one or more thermosetting materials selected for each of the multiple extruders.

[0098] Example 20 relates to the three dimensional printer of example 18 or 19, wherein the command to print the target object further indicates a volumetric mix ratio of the one or more thermosetting materials selected for each of the multiple extruders.

[0099] Example 21 relates to a three dimensional printer of any one of Examples 18-20, further comprising a plurality of material sources configured to supply one or more thermosetting materials to each of the plurality of extruders.

[0100] Aspect 22 relates to the three-dimensional printer of any one of aspects 18 to 21, further comprising a movable arm, wherein multiple extruders are coupled to the movable arm and configured to extrude continuously.

[0101] Example 23 relates to the three dimensional printer of any one of Examples 18 to 22, wherein multiple extruders are used simultaneously to create a single tool path.

[0102] In a twenty-fourth aspect, there is provided a computer implemented method for dynamically controlling a thermosetting three dimensional printer to produce desired material attributes, the computer implemented method being executed on one or more processors, preferably using a computer system according to any one of aspects 1-17, the method including receiving, by the three dimensional printer, preferably according to any one of aspects 18-23, an indication to print a target object using the thermosetting three dimensional printer; accessing a material attribute dataset, the material attribute dataset describing different material properties of a plurality of thermosetting materials being printed; selecting, for each of a plurality of extruders based on the material attribute dataset, one or more thermosetting materials from among a plurality of thermosetting materials for each of the plurality of extruders to form an extrusion; determining an extrusion configuration for the one or more thermosetting materials; and generating commands to cause the plurality of extruders of the thermosetting three dimensional printer to implement the extrusion configuration while printing the target object.

[0103] Example 25 relates to the computer-implemented method of example 24, wherein the plurality of extruders includes a first extruder having a first set of extrusion properties and a second extruder having a second set of extrusion properties, and determining the extrusion configuration includes configuring the first extruder to extrude a material having the first set of material properties and configuring the second extruder to extrude a material having the second set of material properties.

[0104] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are considered in all respects to be merely illustrative and not restrictive. The scope of the present invention is therefore indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are intended to be embraced within their scope.

Claims

1. 1. A computer system for dynamically controlling printing parameters in a multi-extruder three dimensional printer, comprising: one or more processors; and one or more computer readable media having executable instructions stored thereon, the executable instructions, when executed by the one or more processors, causing the computer system to perform at least: receiving indications for printing a target object with the three dimensional printer; accessing a material attribute dataset, the material attribute dataset describing different material properties of a plurality of thermosetting materials or blends thereof; for each of the plurality of extruders based on the material attribute data set; selecting one or more thermosetting materials from among the plurality of thermosetting materials for each of the plurality of extruders to form an extrudate; determining an extrusion configuration for the selected one or more thermoset materials; generating commands to cause the multiple extruders of the three dimensional printer to implement the extrusion configurations of the multiple extruders while printing the target object.

2. The plurality of extruders are a first extruder having a first set of extrusion properties; a second extruder having a second set of extrusion properties; Determining the extrusion configuration of each of the plurality of extruders configuring the first extruder to extrude a material having a first set of material properties; and configuring the second extruder to extrude a material having a second set of material properties.

3. the target object having a plurality of portions having different material properties, and for each of the plurality of portions, the computer system: selecting one or more thermosetting materials from among a plurality of thermosetting materials to form an extrudate; selecting one of the plurality of extruders; 3. The computer system of claim 1 or 2, further configured to: determine a particular extrusion configuration of the selected extruder and the extrusion body.

4. the target object having a plurality of portions having different material properties, and for each of the plurality of portions, the computer system: selecting one or more thermosetting materials from among a plurality of thermosetting materials to form an extrudate; selecting one of the plurality of extruders; The computer system of any one of claims 1 to 3, further configured to: determine a particular extrusion configuration of the selected extruder and the extrusion body.

5. 5. The computer system of claim 1, wherein for each of the plurality of portions, the computer system is further configured to determine a volumetric mix ratio of the selected one or more thermosetting materials, and the command is configured to cause the selected extruder to deliver the selected one or more thermosetting materials in the determined volumetric mix ratio.

6. 6. The computer system of claim 1, wherein the different material properties include at least flowable or gel properties, or mixtures thereof, of the multiple thermosetting materials in different ratios before co-reaction.

7. 7. The computer system of claim 1, wherein the different material properties include at least hardness, flexibility, tensile strength, color, temperature resistance, sound deadening, expansion, flame retardancy, shatter resistance, expansion, electrical conductivity of the multiple thermoset materials in different ratios after co-reaction, or mixtures thereof.

8. The computer system of any one of claims 1 to 7, wherein for each of the plurality of extruders, the extrusion configuration comprises at least one of an extrusion speed, an extrusion timing, or an extrusion path.

9. The computer system of any one of claims 1 to 8, wherein the multiple extruders are used in series to create a single tool path.

10. The computer system of any one of claims 1 to 9, wherein each of the plurality of extruders is coupled to a separate set of material sources.

11. calculating an offset between a first extruder selected from the plurality of extruders and a second extruder selected from the plurality of extruders; receiving a command to switch extrusion from the first extruder to the second extruder; 11. The computer system of claim 1, further comprising: utilizing the offset to position the second extruder at a location relative to the first extruder prior to extruding material from the second extruder.

12. receiving a command to switch extrusion of a first material from the first extruder to a second material; Retrieving a purge entry from the material database, the purge entry indicating an amount and configuration of extrusion required to purge the first material from the first extruder; positioning the first extruder in a purge zone; 12. The computer system of claim 1, further comprising: purging an amount of extrusion required to purge the first material from the first extruder.

13. A three-dimensional printer, a plurality of extruders, each configured to extrude a different extrudate; one or more processors; and one or more computer readable media having executable instructions stored thereon, the executable instructions, when executed by the one or more processors, causing the three dimensional printer to perform at least: Receiving a command to print a target object; for each of the plurality of extruders based on the commands, selecting one or more thermosetting materials from a plurality of thermosetting materials; mixing the one or more selected thermosetting materials to form an extrudate; Setting an extrusion configuration; and extruding the extrusion body based on the extrusion configuration.

14. 14. The three dimensional printer of claim 13, wherein the command to print the target object indicates the one or more thermoset materials selected for each of the multiple extruders.

15. 15. The three dimensional printer of claim 13 or 14, wherein the command for printing the target object further indicates a volumetric mix ratio of the one or more thermosetting materials selected for each of the multiple extruders.

16. 16. The three dimensional printer of any one of claims 13 to 15, further comprising a plurality of material sources configured to supply one or more thermosetting materials to each of the plurality of extruders.

17. 17. The three dimensional printer of any one of claims 13 to 16, further comprising a moveable arm, the multiple extruders being coupled to the moveable arm, the multiple extruders being configured to extrude in series.

18. A three dimensional printer according to any one of claims 13 to 17, wherein the multiple extruders are used simultaneously to create a single tool path.

19. 1. A computer-implemented method for dynamically controlling a thermoset three dimensional printer to produce desired material properties, said computer-implemented method running on one or more processors, said method comprising: receiving an indication for printing a target object with the thermosetting three dimensional printer; accessing a material attribute dataset, the material attribute dataset describing different material properties of a plurality of thermoset materials being printed; for each of a plurality of extruders based on the material attribute data set; selecting one or more thermosetting materials from among the plurality of thermosetting materials for each of the plurality of extruders to form an extrudate; determining an extrusion configuration of the one or more thermoset materials; generating commands to cause the multiple extruders of the thermoset three dimensional printer to implement the extrusion configuration while printing the target object.

20. The plurality of extruders are a first extruder having a first set of extrusion properties; a second extruder having a second set of extrusion properties; Determining the extrusion configuration configuring the first extruder to extrude a material having a first set of material properties; and configuring the second extruder to extrude a material having a second set of material properties.

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