Manufacturing system and method for three dimensional printing

Abstract

A three dimensional (3D) printing system and method, and more particularly, to a system and method for efficient 3D printing of components for powder injection via standard feedstock.SOLUTION: A three dimensional (3D) printing system may comprise a frame and an additional component configured to couple to the frame. The additional components may comprise a first extrusion unit, a second extrusion unit, and / or a third extrusion unit. The 3D printing system may be part of a hybrid computer numerically controlled (CNC) machining / 3D printing system, and may be configured to manufacture 3D components autonomously from start to finish. The additional component may comprise a heating system including a hot air blower.SELECTED DRAWING: Figure 2D

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 035,335, entitled "HYBRID CNC MACHINING / 3D PRINTING SYSTEMS AND METHODS THEREOF," filed June 5, 2020. The disclosure of the foregoing application is incorporated herein by reference in its entirety, including but not limited to the portions specifically set forth below, except for any disclaimer or disclaimer of subject matter, and except to the extent the incorporated material contradicts the express disclosure herein, in which case the language of the present disclosure shall control.

[0002] FIELD OF THE INVENTION The present disclosure relates to three-dimensional (3D) printing systems and methods, and more particularly to systems and methods for efficiently 3D printing components for powder injection via standard feedstock. [Background technology]

[0003] Computer numerically controlled (CNC) machines process pieces of material (e.g., metal, plastic, wood, ceramic, or composite materials) to meet specifications without a manual operator by following coded, programmed instructions. CNC machines utilize drills, saws, etc. to machine materials to meet desired specifications. In contrast, 3D printing devices are configured for additive manufacturing, where material is built up by sequentially extruding multiple layers. While 3D printing devices can be utilized sequentially, they are distinct devices from CNC machines. This can delay the production of the final product and potentially add additional work. Therefore, hybrid CNC machining / 3D printing systems and methods may be desirable. Summary of the Invention

[0004] Disclosed herein is an extrusion device for use in a 3D printing system or a hybrid CNC machining / 3D printing system. The extrusion device may include a heating system configured to heat a deposited layer prior to depositing a second layer. In various embodiments, the heating system can facilitate greater bonding of the deposited layers compared to typical extrusion devices for 3D printing applications. In various embodiments, the heating system is independent and adaptable to be coupled to a typical computer numerically controlled (CNC) machining device via a mount or the like. In various embodiments, the extrusion device includes an actuator configured to translate the extrusion device toward or away from a workpiece.

[0005] In various embodiments, the extrusion devices disclosed herein may be adaptable for use in three-dimensional (3D) printing devices or hybrid computer numerically controlled (CNC) machining / 3D printing devices. In various embodiments, the 3D printing device, whether hybrid or not, may include a spindle or tool holder configured to exchange various extrusion devices, or the 3D printing device may include multiple tool holders to simultaneously hold multiple extrusion devices.

[0006] The extrusion devices disclosed herein may be used for a variety of purposes (i.e., initial layers of additional material to create the general shape, finer layers to define the finer features of each component, and / or support layers to provide additional structural support in unsupported areas). According to various embodiments, extrusion devices can be utilized in succession (by swapping extrusion devices in the case of interchangeable systems, or immediately in the case of systems with multiple extrusion devices) to create robust 3D printed components.

[0007] Disclosed herein is a hybrid computer numerically controlled (CNC) machining / three-dimensional (3D) printing system. The system may include a frame having a spindle, the spindle configured to receive an ablation component, a first extrusion unit coupled to the frame, the first extrusion unit including a first heating system, the heating system heating a deposited layer prior to depositing a second layer, and a controller in electrical communication with the frame, the spindle, and the first extrusion unit.

[0008] In various embodiments, the controller is operable to direct the first extrusion unit to deposit the material into a predetermined shape and to direct the spindle to machine the material via the subtractive component based on desired specifications. The hybrid CNC machining / 3D printing system may further include a second extrusion unit coupled to the frame, the second extrusion unit comprising a second heating system via the first heating system. The first extrusion unit may comprise a first nozzle, and the second extrusion unit may comprise a second nozzle, the first nozzle having a first diameter that may be larger than a second diameter of the second nozzle. In various embodiments, the controller is in electrical communication with the second extrusion unit, and the controller is operable to direct the first extrusion unit to deposit the bulk material into a predetermined shape, to direct the spindle to machine the bulk material via the subtractive component based on desired specifications, and to deposit a second material to fill voids in the bulk material or to deposit support material to add support to the predetermined shape. The system may further include a third extrusion unit coupled to the spindle, the third extrusion unit including a third heating system that is in accordance with the first heating system. In various embodiments, a controller is in electrical communication with the second extrusion unit, the controller being operable to: direct the first extrusion unit to lay down the bulk material into a predetermined shape; direct the subtractive component to machine the bulk material based on desired specifications; direct the second extrusion unit to deposit a second material to fill voids within the bulk material; and direct the third extrusion unit to deposit a support material to add support to the predetermined shape.

[0009] Disclosed herein are methods for manufacturing three-dimensional (3D) components. The method may include: depositing a first material into a predetermined shape through a first extrusion unit of a manufacturing system; machining the first material to desired specifications through the manufacturing system; and depositing a second material to fill voids within the first material through a second extrusion unit of the manufacturing system. The method may further include conforming the first material through a conforming / condensing tool of the manufacturing system. The method may further include depositing a support material through a third extrusion unit of the manufacturing system to add support to the predetermined shape. In various embodiments, the first extrusion unit includes a first nozzle, and the second extrusion unit includes a second nozzle, the first nozzle having a first diameter greater than a second diameter of the second nozzle. The method may further include replacing the first extrusion unit with the second extrusion unit before depositing the second material. The first and second extrusion units may each comprise a heating system comprising a hot air blower configured to heat the material during deposition.

[0010] Disclosed herein is a method for manufacturing a three-dimensional (3D) component. The method includes depositing a first material into a predetermined shape through a first extrusion unit of a manufacturing system, the first extrusion unit including a first nozzle; and extruding a first material through the manufacturing system into a predetermined shape. The method may include replacing the first extrusion unit with a second extrusion unit, the second extrusion unit including a second nozzle, the first nozzle having a first diameter greater than a second diameter of the second nozzle, and depositing the second material through the second extrusion unit of the manufacturing system to fill voids within the first material. The method may further include condensing via a condensing device of the manufacturing system. Condensing the first material may further include simultaneously heating the first material via the condensing device. In various embodiments, depositing the first material further includes depositing filaments within the first material via a spool feeder of the manufacturing system.

[0011] Disclosed herein is a condensation device for use in a three-dimensional printing system. The condensation device may include a first spindle taper adaptable to be operably coupled to a spindle of a computer numerically controlled (CNC) machine, a nozzle defining a tip, a housing coupled to the nozzle, a fluid drive system disposed between the first spindle and the nozzle, the fluid drive system configured to drive a fluid toward a fluid outlet disposed proximate to the tip of the nozzle, and a material forming apparatus disposed proximate to the tip of the nozzle.

[0012] In various embodiments, the condensing device may include a piping system configured to couple to a heating system of the CNC machine. The piping system may be configured to receive hot air through the CNC machine during operation of the condensing device. The condensing system may further include a damping system coupled to the material forming apparatus. The damping system may include a strut. The fluid drive system may include a turbine configured to rotate relative to the housing.

[0013] Disclosed herein is an extrusion device for use in a three-dimensional printing system. The extrusion device may include a drive motor, an auger coupled to the drive motor, a housing assembly within which the auger is disposed and configured to translate material to be deposited through the housing assembly, a hopper in fluid communication with the housing assembly, a heating system coupled to the housing assembly to heat a deposited layer prior to depositing a second layer, and at least one of a mount or an actuator, wherein the at least one of the mount or actuator can be removably coupled to a computer numerically controlled (CNC) machining device.

[0014] In various embodiments, the heating system further comprises a hot air blower in fluid communication with the hot air duct. The extrusion device may further comprise a nozzle in fluid communication with the housing assembly. The extrusion device may further comprise an outlet of the hot air duct, the outlet being disposed radially outward of the nozzle. The heating system may further comprise a first hot air blower disposed radially outward of the housing assembly. The heating system may further comprise a second hot air blower disposed radially outward of the housing assembly. The extrusion device may further comprise a spool feeder system configured to feed the filament into the housing assembly and intersect with the material to be deposited. The spool feeder system may comprise a spool, a second drive motor, and a shaft. The second drive motor may be configured to drive the shaft, and the spool is configured to rotate in response to the shaft being driven.

[0015] The foregoing features and elements can be combined in various combinations without exclusivity unless expressly stated otherwise. These features and elements and their operation will become more apparent in light of the following description and accompanying drawings. It should be understood, however, that the following description and drawings are intended to be illustrative in nature and non-limiting. The contents of this section are intended as a simplified introduction to the disclosure and are not intended to limit the scope of any claims. Reference is made to the following description and accompanying drawings. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 illustrates a method for 3D printing a component, according to various embodiments. [Figure 2A] FIG. 1 illustrates a perspective view of a hybrid computer numerically controlled (CNC) machining / three-dimensional (3D) printing system, according to various embodiments. [Figure 2B]FIG. 1 illustrates a side view of a portion of a hybrid computer numerically controlled (CNC) machining / three-dimensional (3D) printing system, according to various embodiments. [Figure 2C] FIG. 1 illustrates a side view of a portion of a hybrid computer numerically controlled (CNC) machining / three-dimensional (3D) printing system, according to various embodiments. [Figure 2D] FIG. 1 illustrates a side view of a portion of a hybrid computer numerically controlled (CNC) machining / three-dimensional (3D) printing system, according to various embodiments. [Figure 2E] FIG. 1 illustrates a side view of a portion of a three-dimensional (3D) printing system, according to various embodiments. [Figure 2F] FIG. 1 illustrates a perspective view of a portion of a three-dimensional (3D) printing system, according to various embodiments. [Figure 3] 1A-1C are perspective views of an extrusion device according to various embodiments. [Figure 4] 1A-1C are perspective cross-sectional views of extrusion devices according to various embodiments. [Figure 5] 1A-1C are perspective views of an extrusion device according to various embodiments. [Figure 6] 1A-1C are bottom views of an extrusion device, according to various embodiments. [Figure 7A] 1A-1C illustrate an extrusion device having a spool feeder system according to various embodiments. [Figure 7B] FIG. 1 is a detailed view of a spool feeder system for an extrusion device, according to various embodiments. [Figure 8A] 1A-1C are cross-sectional views of a portion of an extrusion device according to various embodiments. [Figure 8B] 1A-1C are cross-sectional views of a portion of an extrusion device according to various embodiments. [Figure 8C] 1A-1C are cross-sectional views of a portion of an extrusion device according to various embodiments. [Figure 9A] 1A-1C are side views of a condensation / matching tool according to various embodiments. [Figure 9B] 1A-1C are perspective views of a condensation / matching tool according to various embodiments. [Figure 9C]1A-1C are cross-sectional views of condensation / matching tools according to various embodiments. [Figure 10] 1A-1C are side views of a condensation / matching tool according to various embodiments. [Figure 11A] 1A-1C illustrate the installation of a condensation / matching tool in a tool holder of a CNC machine, according to various embodiments. [Figure 11B] 1A-1C illustrate the installation of a condensation / matching tool in a tool holder of a CNC machine, according to various embodiments. [Figure 11C] 1A-1C illustrate the installation of a condensation / matching tool in a tool holder of a CNC machine, according to various embodiments. [Figure 11D] 1A-1C illustrate the installation of a condensation / matching tool in a tool holder of a CNC machine, according to various embodiments. [Figure 11E] 10A-10C illustrate replacing a condensation / conformity tool with a subtractive component, according to various embodiments. [Figure 11F] 10A-10C illustrate replacing a condensation / conformity tool with a subtractive component, according to various embodiments. [Figure 11G] 10A-10C illustrate replacing a condensation / conformity tool with a subtractive component, according to various embodiments. [Figure 11H] 10A-10C illustrate replacing a condensation / conformity tool with a subtractive component, according to various embodiments. [Figure 12] FIG. 1 is a schematic block diagram of a manufacturing system, in accordance with various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description is merely of various exemplary embodiments and is not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the following description is intended to provide convenient illustrations for implementing various embodiments, including the best mode. It should be understood that various changes can be made in the function and arrangement of elements described in these embodiments without departing from the principles of the present disclosure.

[0018] For the sake of brevity, conventional techniques and components may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in an example system and / or its components.

[0019] In various embodiments, various components are disclosed herein for manufacturing more detailed three-dimensional components in a more efficient manner compared to typical systems and methods. For example, an improved extrusion device is disclosed herein that is adaptable to be attached to and / or retrofitted to a typical CNC machine. Additionally, the improved extrusion device, according to various embodiments, may include an independent heating system, such as a hot air blower, configured to heat a layer being deposited or a layer below a layer being deposited during material deposition to create a stronger bond during additive processing. In various embodiments, the improved extrusion device may further include a spool feeder in communication with the nozzle of the improved extrusion device. In this regard, the spool feeder may be configured to feed a filament into the nozzle and deposit it along with the material being deposited through the extrusion device to create a stronger and / or more rigid composite component compared to the material itself.

[0020] Also disclosed herein, according to various embodiments, is a condensing / conforming device configured to condense and / or conform material after a deposition step in a 3D printing process. In various embodiments, the condensing / conforming device is configured for subsequent use from an extrusion device disclosed herein. In various embodiments, the condensing / conforming tool comprises a heating system configured to heat previously deposited material during the deposition step to promote greater bonding between layers and a smoother, more uniform component compared to typical systems and processes.

[0021] In various embodiments, a method for manufacturing a 3D component via a manufacturing system is disclosed herein. The manufacturing system may include a hybrid computer numerically controlled (CNC) machining / 3D printing device including a machining center (e.g., a spindle taper), a first extrusion unit, a second extrusion unit, and / or a third extrusion unit. "Hybrid," as disclosed herein, refers to a system configured for granular material deposition, material removal, and / or material condensation, according to various embodiments. In various embodiments, the hybrid CNC machining / 3D printing device may be configured to efficiently manufacture high-quality components without manual assistance during the process. In this regard, the manufacturing system may be configured to define a rough shape of the final component using a first extrusion unit, mill the rough shape to predetermined specifications using a mill, fill any voids using a second extrusion unit, and / or add support material to unsupported areas using a third extrusion unit. The first extrusion unit, the second extrusion unit, and the third extrusion unit may be substantially similar. Each extrusion unit may include a removable nozzle. The removable nozzle allows you to adjust the nozzle diameter for each extrusion unit. Thus, according to various embodiments, a first extrusion unit may be configured to deposit bulk material using a larger diameter nozzle, and a second extrusion unit may be configured to deposit finer particles using a smaller diameter nozzle.

[0022] In various embodiments, the first extrusion unit, the second extrusion unit, and the third extrusion unit may be retrofitted to a typical CNC machine, resulting in a hybrid CNC machining / 3D printing device. In various embodiments, the first extrusion unit, the second extrusion unit, and the third extrusion unit may be integral with the hybrid CNC machining / 3D printing device. In various embodiments, the first extrusion unit, the second extrusion unit, and the third extrusion unit may comprise a linear actuator. The linear actuator may be configured to translate the respective extrusion unit before or during the layering and / or deposition steps of the manufacturing methods described herein. While described herein as comprising a mill, any subtractive machining component of a CNC machining device is within the scope of the present disclosure. For example, a lathe configured for turning, facing, parting, grooving, drilling, milling, and / or any combination of subtractive machining components is within the scope of the present disclosure.

[0023] Referring now to FIG. 1 , a method for manufacturing a 3D component is illustrated, according to various embodiments. The method 100 includes depositing a first material into a predetermined shape via a manufacturing system (step 102). The manufacturing system, according to various embodiments, can include a hybrid CNC machining / 3D printing device, or a 3D printing device and a CNC machine. The manufacturing system can include a mill and at least one extrusion unit. The mill can be configured for subtractive manufacturing, and the at least one extrusion unit can be configured for additive manufacturing. The predetermined shape can be the rough shape of the 3D component. The first material can be deposited via a first extrusion unit of the 3D printing device. The first material can include a ceramic injection molding (CIM) powder, a metal injection molding (MIM) powder, a polymer-based material, or any other 3D printing material known in the art. The first extrusion unit can be configured to deposit a bulk of the first material in the rough shape of the 3D component.

[0024] In various embodiments, method 100 further includes condensing or conforming the first material (step 103) via a manufacturing system. While condensing / conforming is shown in step 104 as prior to machining, the disclosure is not limited thereto. For example, according to various embodiments, condensing or conforming step 103 may be utilized after any other step of method 100. The manufacturing system may further include a condensing / conforming tool, as described further herein. The condensing / conforming tool may be compatible with a CNC tool changer, as described further herein. In this regard, according to various embodiments, various condensing / conforming tools may be utilized based on the particular application.

[0025] In various embodiments, method 100 further includes machining the first material to desired specifications (step 104) via a manufacturing system. In various embodiments, the machining may include turning or drilling, or more preferably milling. The machining component, such as a mill, may be a component of a hybrid CNC machining / 3D printing device. The desired specifications may correspond to desired geometric constraints of the 3D component to be printed. In this regard, the machining step may result in a machined component that is within the desired specifications of the 3D component to be manufactured.

[0026] In various embodiments, the method 100 includes depositing the second material through a manufacturing system, The method further includes filling voids within the first material and / or creating finer features of the 3D component (step 106). In various embodiments, step 106 may be performed before or after steps 103 and 104. The second material may be deposited via a second extrusion unit of the hybrid CNC machining / 3D printing device. The second material may include ceramic injection molding (CIM) powder, metal injection molding (MIM) powder, polymer-based material, or any other 3D printing material known in the art. The second material may be the same as the first material. The second extrusion unit may be configured to deposit a smaller amount of the second material than the first extrusion unit. For example, the second extrusion unit may include a nozzle having a smaller cross-sectional diameter than the nozzle of the first extrusion unit. In this regard, according to various embodiments, the second extrusion unit may be configured to deposit a smaller diameter material than the first extrusion unit for finer features and / or to fill voids left by the first material.

[0027] In various embodiments, the method 100 further includes depositing a support material (step 108) via a manufacturing system to add support to the predetermined shape. The second material may be deposited via a third extrusion unit of a hybrid CNC machining / 3D printing device. In various embodiments, the 3D component may include a flange or any other feature that may require additional support to prevent collapse of the feature. In this regard, a support material may be deposited to provide additional support to the 3D component. In various embodiments, the support material may be a different material from the first material and / or the second material. For example, the support material may include a polyethylene glycol (PEG) material, a polyvinyl alcohol (PVA) material, etc. In various embodiments, the support material may include a material configured to be thermally removed, such as a wax material or any other material that can be removed upon exposure to heat. Also, in various embodiments, removal of the support material by a solvent-based process is within the scope of the present disclosure.

[0028] Although described herein with three extrusion units configured for additive manufacturing, one milling component configured for subtractive manufacturing, and one condense / fit tool, the manufacturing systems herein may include any combination of subtractive manufacturing components, condense / fit tools, and additive manufacturing components on a single hybrid CNC machining / 3D printing device. For example, according to various embodiments, a hybrid CNC machining / 3D printing device includes at least one subtractive manufacturing component (e.g., a mill, lathe, drill, etc.), at least one condense / fit tool, and / or at least one additive manufacturing component (e.g., a first extrusion unit, a second extrusion unit, a third extrusion unit, etc.).

[0029] In various embodiments, the method 100 disclosed herein is faster and more efficient than typical manufacturing processes. For example, according to various embodiments, by utilizing a hybrid multi-function system, a 3D printed component does not need to be changed between a 3D printing machine and a CNC machine to switch between performing additive and subtractive steps. In this regard, according to various embodiments, significant time can be saved during the method 100 of FIG. 1 . Furthermore, according to various embodiments, through the use of conformal / condensing tools throughout the process 100 (e.g., step 103) and / or the application of heat throughout the deposition steps (e.g., steps 102, 106, 108), the method 100 can achieve tighter tolerances and / or stronger bonds between layers.

[0030] 2A, a perspective view of a manufacturing system 200 configured to manufacture 3D components according to the method 100 of FIG. 1 is shown in accordance with various embodiments. The manufacturing system 200 may include a hybrid CNC machining / 3D printing device 201. In various embodiments, the manufacturing system 200 may include a hybrid CNC machining / 3D printing device 201 configured for additive manufacturing. The manufacturing process may include a component (e.g., first extrusion unit 210) and a CNC tool (e.g., subtractive component 240 configured for a subtractive manufacturing process, such as a mill 241, lathe, drill, etc.). While shown as subtractive component 240 in FIG. 2A , the disclosure is not limited thereto. For example, in various embodiments, subtractive component 240 may be exchanged for a condensation / adaptation tool via hybrid CNC machining / 3D printing device 201, as described further herein. In this regard, in response to the exchange for the condensation / adaptation tool, hybrid CNC machining / 3D printing device 201 may be configured to adapt the 3D printed component at various stages in the manufacturing process (i.e., during manufacturing step 103 of method 100), as described further herein. In various embodiments, the hybrid CNC machining / 3D printing device 201 may include multiple additive components (e.g., first extrusion unit 210) and / or multiple CNC tools (e.g., multiple subtractive components 240, a single subtractive component 240 and a condensation / fitting tool, etc.), as previously described herein. In this regard, the hybrid CNC machining / 3D printing device 201 is configured to more efficiently produce high-quality 3D components without human intervention during the additive, condensation / fitting, and / or subtractive steps of the manufacturing process (e.g., method 100 of FIG. 1 ). In various embodiments, the hybrid CNC machining / 3D printing device 201 is configured to subtractively manufacture, additively manufacture, and / or condense / fit each component along three to five axes (e.g., along X, Y, Z axes, along X, Y, Z axes and rotational axes, along X, Y, Z axes and two rotational axes, or along as many axes as current CNC machines are capable of). In various embodiments, the manufacturing system 200 includes a vertical machining system (e.g., the hybrid CNC machining / 3D printing device 201 of FIG. 2A) or a horizontal machining system (e.g., the hybrid CNC machining / 3D printing device 203 of FIG. 2D).

[0031] The hybrid CNC machining / 3D printing device 201 may be configured to print the rough shape of the 3D component using a first extrusion unit 210 (e.g., step 102 of method 100 of FIG. 1 ). In this regard, the first extrusion unit 210 may be configured to receive the first material via a hopper or the like, as described further herein. In various embodiments, the hybrid CNC machining / 3D printing device 201 may be configured to machine the rough shape of the 3D component to desired specifications using subtractive components 240 (e.g., step 104 of FIG. 1 ).

[0032] In various embodiments, the hybrid CNC machining / 3D printing device 201 may be configured to deposit a second material to fill voids within the first material (e.g., step 106 of FIG. 1 ). In this regard, according to various embodiments, the hybrid CNC machining / 3D printing device 201 may include a second extrusion unit 220 configured to receive the second material via a hopper, or the first extrusion unit 210 may be configured to change the diameter of its respective nozzle and receive the second material. In various embodiments, the first material is the same as the second material. In various embodiments, the second material may be of finer diameter / grain size than the first material. In this regard, the second material may be configured for more detailed, additional features of the 3D component. In various embodiments, the hybrid CNC machining / 3D printing device 201 may be configured to deposit a support material to add support to the predetermined shape (e.g., step 108 of method 100 of FIG. 1 ). Thus, the support material may be a different material from the first material and / or the second material.

[0033] In various embodiments, the hybrid CNC machining / 3D printing device 201 further comprises a first frame 202, a second frame 204, and a work table 206. The second frame 204 and the work table 206 may each be coupled to the first frame 202. The first frame 202 is a fixed frame. In various embodiments, , the second frame 204 includes a spindle 205. The spindle 205 comprises a motor, a taper for holding a tool (referred to herein as a "tool holder" and / or "spindle"), and a shaft that holds the separate components together. In various embodiments, the second frame 204 may be configured to move relative to the first frame 202. In this regard, the second frame 204 may be a moving frame according to various embodiments. In various embodiments, the work table 206 may be configured to move relative to the frames 202, 204. In this regard, the frames 202, 204 may be fixed in various embodiments. In various embodiments, both the work table 206 and the second frame 204 may be configured to move relative to the first frame 202. During an additive step (e.g., steps 102, 106, and / or 108 of FIG. 1 ), material may be deposited on work table 206, during a condensing / conforming step (e.g., step 103), material may be condensed / conformed on work table 206, and / or during a subtractive step (e.g., step 104), material may be machined on work table 206.

[0034] While extrusion units 210, 220, 230 and subtractive component 240 are shown as coupled to the same frame (e.g., frame 204), the present disclosure is not limited in this regard. For example, with brief reference to FIG. 2D , according to various embodiments, extrusion units 210, 220, 230 may be coupled to a first frame 207, and subtractive component 240 may be coupled to a spindle disposed on a second frame 209. According to various embodiments, hybrid CNC machining / 3D printing device 203 of manufacturing system 200, when coupled to a separate frame (e.g., frames 207, 209 of FIG. 2D ), may be configured to perform additional steps (e.g., steps 102, 106, and / or 108) substantially simultaneously with the subtractive step (e.g., step 104), resulting in a more efficient manufacturing process.

[0035] In various embodiments, ablative component 240, first extrusion unit 210, second extrusion unit 220, third extrusion unit 230, spindle 205, and / or work table 206 are in electrical communication with controller 208. The controller may be located anywhere on hybrid CNC machining / 3D printing device 201. In various embodiments, the controller may be located on spindle 205, although the disclosure is not limited in this respect.

[0036] Referring now to FIG. 2B , a side view of a hybrid CNC machining / 3D printing device 201 of manufacturing system 200 is shown with an extrusion unit (e.g., first extrusion unit 210) in a first position, according to various embodiments. While shown as including first extrusion unit 210, any extrusion unit may be configured according to FIG. 2B . For example, second extrusion unit 220 and / or third extrusion unit 230 may be configured according to first extrusion unit 210 of FIG. 2B . In various embodiments, first extrusion unit 210 includes an actuator 212 (e.g., a linear actuator). In various embodiments, actuator 212 is configured to translate the extrusion unit (e.g., first extrusion unit 210) relative to the housing of the extrusion unit. For example, referring now to FIG. 2C, the first extrusion unit 210 may translate from a first position (e.g., FIG. 2B) to a second position (e.g., FIG. 2C) during the lamination and / or deposition steps (e.g., steps 102, 106, and / or 108) of the method 100 of FIG. 1.

[0037] In various embodiments, the extrusion units disclosed herein (e.g., extrusion units 210, 220, 230) are not limited to hybrid CNC machining / 3D printing devices 201, 203. For example, referring now to FIGS. 2E-2F, extrusion units 210, 220, 230 may be configured for and adapted for 3D printing device 211. In this regard, extrusion units 210, 220, 230 may be used in a 3D printing system, a hybrid machining / 3D printing system, or the like. While illustrated as having multiple extrusion units (e.g., extrusion units 210, 220, 230) all simultaneously coupled to frame 204 in FIG. 2A , the disclosure is not limited in this respect. For example, as shown in FIGS. 2E-F , additional tool holders 213 of 3D printing device 211 may be independently coupled to each extrusion unit (e.g., extrusion units 210, 220, 230) disclosed herein and adaptable to replace extrusion units when moving to the next step of method 100 in FIG. 1 . Although shown as part of 3D printing device 211, according to various embodiments, a single tool holder 213 for extrusion units 210, 220, 230 may be utilized in hybrid CNC machining / 3D printing devices 201, 203.

[0038] Referring now to FIG. 3 , a perspective view of an extrusion device 300 is shown according to various embodiments. In various embodiments, the first extrusion unit 210, the second extrusion unit 220, and / or the third extrusion unit 230 can follow the extrusion device 300. In various embodiments, the extrusion device 300 includes a drive motor 310, a hopper 320, a housing assembly 330, a heating system 340, and a nozzle 350. In various embodiments, the drive motor 310 is configured to drive an auger, screw, plunger, etc., disposed within the housing assembly 330. The hopper 320 may be in fluid communication with the housing assembly 330. In this regard, material is fed into the housing assembly 330 through the hopper 320. The housing assembly 330 may be configured to be attached to a continuous feed system (i.e., an autoloader, as is common in plastic injection molding) configured to couple to the hopper 320. A continuous feed system may be configured to feed material into housing assembly 330 via hopper 320, and drive motor 310 may extrude material through nozzle 350 during layering or deposition steps (e.g., steps 102, 106, and / or 108) of method 100 of FIG. 1 . Housing assembly 330 may be configured to attach to a CNC machine and convert the CNC machine into a hybrid CNC machining / 3D printing device (e.g., hybrid CNC machining / 3D printing device 201 of FIGS. 2A-2C , or hybrid CNC machining / 3D printing device 203 of FIG. 2D , or 3D printing device 211 of FIG. 2E ). For example, extrusion device 300 may further include mount 360. Mount 360 may be configured to attach to a typical CNC machine by any method known in the art (e.g., fasteners, welding, brazing, casting, machining, etc.).

[0039] In various embodiments, heating system 340 includes hot air blower 342, heater housing 344, and hot air duct 346. As used herein, "hot air" refers to air heated to approximately 38°C (100°F) to 200°C (392°F). In various embodiments, hot air blower 342 is housed within heater housing 344 and configured to output hot air through hot air duct 346. The hot air disposed through the hot air duct may be configured to heat a layer of material beneath a layer being deposited during a lamination step (e.g., step 102) of method 100 of FIG. 1 and / or to heat a layer of material beneath a layer during a deposition step (e.g., steps 102, 106, 108) of method 100 of FIG. 1. In this regard, the output of hot air duct 346 may be circumferentially disposed around nozzle 350. Thus, the hot air can directly contact the layer below the layer being deposited (e.g., during steps 102, 106, 108 of method 100 of FIG. 1), thereby promoting adhesion of the bottom layer to the layer being deposited. In various embodiments, the hot air blower is a separate and independent component from the CNC machine or 3D printing device, such that extrusion device 300 includes its own independent heating source. In this regard, according to various embodiments, hot air blower 342 facilitates compatibility of the extrusion device with typical CNC machines lacking a heating mechanism. It is possible.

[0040] Although described herein as comprising a hot air blower, any heating component capable of locally heating the material being deposited is within the scope of the present disclosure. In various embodiments, by heating a layer below the layer being deposited, a system for heating the work environment during an additive manufacturing step (e.g., steps 102, 106, 108 of method 100 of FIG. 1 ) can be eliminated. Additionally, according to various embodiments, by having a heating system 340 coupled to housing assembly 330 of extrusion device 300, extrusion device 300 can be retrofitted to a typical CNC machine, converting the CNC machine into a hybrid CNC machining / 3D printing device (e.g., hybrid CNC machining / 3D printing device 201 of FIG. 2A or hybrid CNC machining / 3D printing device 203 of FIG. 2D or 3D printing device 211 of FIG. 2E ).

[0041] In various embodiments, the housing assembly 330 includes a heat sink 332 and a heater band / element 334. In various embodiments, the heater band / element 334 is configured to indirectly heat the material being extruded through the housing assembly 330 of the extrusion device 300 through the heat sink 332. For example, the heater band / element 334 may be electrically coupled to a controller (e.g., controller 208 of FIG. 2A ). The controller can send a signal to the heater band / element 334 to initiate electrical heating. The heater band / element 334 can electrically heat the exterior surface of the heat sink 332. The heat sink 332 can be any material known in the art. In various embodiments, the heat sink 332 can conduct heat generated from the heater band / element 334 and / or transfer heat to the material being extruded through the extrusion device 300. In various embodiments, the heat bands / elements 334 may comprise a low-conductivity material to minimize heat transfer upwardly through the housing of the device to prevent the material from melting and clogging the hopper. In this regard, during the lamination and / or deposition steps (e.g., steps 102, 106, 108) of the method 100 of FIG. 1 , the material being laminated or deposited may be heated via the heater bands / elements 334 during extrusion from the extrusion device 300 or via the heating system 340 after being laminated or deposited. In various embodiments, by heating during extrusion, the extrusion device 300 can facilitate bonding during the deposition and / or lamination steps (e.g., steps 102, 106, 108 of the method 100 of FIG. 1 ).

[0042] In various embodiments, extrusion device 300 may further include a speed controller 370. Speed ​​controller 370 may be electrically coupled to drive motor 310. In various embodiments, speed controller 370 is configured to vary the extrusion speed of drive motor 310. In this regard, speed controller 370 may be adjusted to increase or decrease the extrusion speed of the drive motor based on the desired application of extrusion device 300. In various embodiments, speed controller 370 may be in electrical communication with a controller (e.g., controller 208 of FIG. 2A ) for each hybrid CNC machining / 3D printing device.

[0043] In various embodiments, the housing assembly 330 may further comprise a thermocouple mount 336. The thermocouple mount 336 may be configured to receive a thermocouple mounted thereon, as described further herein. The thermocouple may be configured to monitor the extrusion temperature of the material being disposed through the housing assembly during the lamination and / or deposition steps (e.g., steps 102, 106, 108) of the method 100 of FIG. 1 . In this regard, the heater bands / elements 334 may be adjusted in response to measurements by the respective thermocouples to ensure that the material is heated to the desired temperature during the extrusion process. In various embodiments, the thermocouples are controlled by a controller (e.g., controller 20 of FIG. 1 ). 8).

[0044] Referring now to FIG. 4 , a perspective cross-sectional view of extrusion device 300 is shown, according to various embodiments. In various embodiments, extrusion device 300 further includes an auger 380 disposed within housing assembly 330. Auger 380 may be operably coupled to drive motor 310. In this regard, auger 380 is configured to be rotated about a centerline of auger 380 by drive motor 310. In various embodiments, rotating auger 380 about an axis defined by the auger centerline may cause material to translate downward through housing assembly 330 and out through nozzle 350. In this regard, according to various embodiments, material may be fed into housing assembly 330 through hopper outlet 322, and the material may translate downward in response to rotation of auger 380 about the auger centerline, and the material may be extruded from nozzle 350.

[0045] 5, a perspective view of an extrusion device 500 is shown, according to various embodiments. In various embodiments, the first extrusion unit 210, the second extrusion unit 220, and / or the third extrusion unit 230 can follow the extrusion device 500. In various embodiments, the extrusion device 500 includes a drive motor 310, a hopper 320, a housing assembly 330, a heating system 540, and a nozzle 350. In various embodiments, the heating system 540 includes a first hot air blower 542 disposed radially outward from the housing assembly 330. In various embodiments, any combination of components from the extrusion device 500 and the extrusion device 300 is within the scope of the present disclosure.

[0046] In various embodiments, the first hot air blower 542 is coupled to the housing assembly 330, disposed within a first heated housing 544, and configured to output hot air through a first hot air duct 546. The hot air disposed through the hot air duct may be configured to heat a layer of material below a layer being deposited during a laminating step (e.g., step 102) of the method 100 of FIG. 1 and / or to heat a layer of material below a layer during a deposition step (e.g., steps 102, 106, 108) of the method 100 of FIG. 1. In this regard, the output of the first hot air duct 546 may be disposed circumferentially around the nozzle 350. Thus, the hot air can directly contact a layer below a layer being deposited (e.g., during steps 102, 106, 108 of the method 100 of FIG. 1) to promote adhesion of the bottom layer to the layer being deposited. In various embodiments, by heating a layer below the layer being deposited, systems for heating the work environment during additive manufacturing steps (e.g., steps 102, 106, 108 of method 100 of FIG. 1 ) can be eliminated. Additionally, according to various embodiments, by having a heating system 540 coupled to housing assembly 330 of extrusion device 300, extrusion device 300 can be retrofitted to a typical CNC machine, converting the CNC machine into a hybrid CNC machining / 3D printing device (e.g., hybrid CNC machining / 3D printing device 201 of FIG. 2A or hybrid CNC machining / 3D printing device 203 of FIG. 2D or 3D printing device 211 of FIG. 2E ).

[0047] In various embodiments, heating system 540 may further include a second hot air blower 552. While shown as including two hot air blowers, any number of hot air blowers is within the scope of the present disclosure. For example, according to various embodiments, extrusion device 500 may include one to four hot air blowers, or more preferably about two hot air blowers. Second hot air blower 552 may be compliant with first hot air blower 542. In various embodiments, second hot air blower 552 may be positioned opposite first hot air blower 542. For example, second hot air blower 552 may be positioned about 180 degrees from first hot air blower 542 around the centerline of each auger of extrusion device 500.

[0048] In various embodiments, extrusion device 500 further comprises a temperature sensor 560. Temperature sensor 560 may be coupled to housing assembly 330 by any method known in the art, such as by fasteners. Temperature sensor 560 may be in operative communication with a plenum within housing assembly 330. In this regard, temperature sensor 560 may monitor the temperature within housing assembly 330 during operation of extrusion device 500 (e.g., during laminating step 102 of method 100 of FIG. 1 and / or during depositing steps 106 and / or 108 of method 100 of FIG. 1).

[0049] In various embodiments, extrusion device 500 further comprises an electrical connector 338 coupled to heater band / element 334. Electrical connector 338 may be configured to be electrically coupled to a controller (e.g., controller 208 of FIG. 2A). In this regard, heater band / element 334 may be programmable to maintain a constant temperature, a temperature range, or to vary the temperature during a manufacturing process (e.g., method 100 of FIG. 1), according to various embodiments.

[0050] 6, a bottom view of an extrusion device 500 is shown in accordance with various embodiments. The extrusion device 500 may further include a first outlet 547 of the first hot air blower 542 in fluid communication with the first hot air duct 546. Similarly, the extrusion device 500 may further include a second outlet 557 of the second hot air blower 552 in fluid communication with the second hot air duct 556. The first outlet 547 and the second outlet 557 may be disposed radially outward from the nozzle outlet 357 of the nozzle 350. In this regard, the heat disposed through the hot air ducts 546, 556 may be configured to heat a layer of material beneath a layer being deposited during a layering step (e.g., step 102) of the method 100 of FIG. 1 and / or to heat a layer of material beneath a layer during a deposition step (e.g., steps 102, 106, 108) of the method 100 of FIG. 1. Thus, the hot air can directly contact the layer below the layer being deposited (e.g., during steps 102, 106, 108 of method 100 of FIG. 1 ), promoting adhesion of the bottom layer to the layer being deposited. In various embodiments, by heating the layer below the layer being deposited, systems for heating the work environment during additive manufacturing steps (e.g., steps 102, 106, 108 of method 100 of FIG. 1 ) can be eliminated.

[0051] 7A, a perspective view of an extrusion device 700 is shown in accordance with various embodiments. In various embodiments, the first extrusion unit 210, the second extrusion unit 220, and / or the third extrusion unit 230 can be extrusion device 700. In various embodiments, extrusion device 700 includes drive motor 310, hopper 320 of FIGS. 3 and 5, housing assembly 330, heating system 540, nozzle 350, and spool feeder system 760. While illustrated with heating system 540, extrusion device 700 is not limited in this respect. For example, extrusion device 700 may include heating system 340 of FIG. 3 in accordance with various embodiments.

[0052] 7B, a detailed view of a spool feeder system 760 is shown according to various embodiments. The spool feeder system 760 includes a spool 762 and a drive motor 764. The spool 762 is coupled to the housing assembly 330. In various embodiments, the spool 762 includes a shaft 766 and a wheel 768. The wheel 768 is configured to rotate about the shaft 766 in response to the drive motor 764 driving the filament 761 toward the nozzle 350 to form an extrusion bead and create a composite material (i.e., the first material and filament 761 of step 102, the second material and filament 761 of step 106, and / or the support material and filament of step 108). In this regard, any of the extrusion devices herein may be configured to extrude a composite material. It may be configured to include a spool feeder system 760 to facilitate 3D printing components.

[0053] In various embodiments, the filaments may include silicon carbon fibers, such as those sold under trademarks such as Nicalon™, Hi-Nicalon™, Hi-Nicalon™ Type S, etc. Silicon carbide fibers can provide high strength, heat and corrosion resistance, and / or improved performance opportunities over ceramic, plastic, and / or metal matrices (e.g., CMC, PMC, MMC as previously described herein).

[0054] 8A-8C, cross-sectional views of various extrusion units 800A, 800B, and 800C are shown, according to various embodiments. In various embodiments, the nozzle diameter / shape may be sized and configured based on the desired function of the respective extrusion unit. For example, the first extrusion unit 210 of FIG. 2A or 2F may include a large-diameter nozzle (e.g., nozzle 850C of FIG. 8C) and may be configured to bulk deposit material during the lamination step (e.g., step 102) of the method 100 of FIG. 1. In various embodiments, the second extrusion unit 220 of FIGS. 2B and 2F may include a small-diameter nozzle (e.g., nozzle 850A of FIG. 8A) and may be configured to deposit particulates during the deposition step (e.g., step 106) of the method 100 of FIG. 1. In various embodiments, the support material may be deposited through a medium diameter nozzle (e.g., nozzle 850B of FIG. 8B) through the third extrusion unit 230 of FIGS. 2B and 2F during the deposition step (e.g., step 108) of the method 100 of FIG. 1. In various embodiments, the support material may be deposited using any diameter nozzle (e.g., nozzles 850A, 850B, 850C of FIGS. 800A-800C).

[0055] 9A-9C, various views of a condensation / conform tool 250 are shown, according to various embodiments. In various embodiments, the condensation / conform tool 250 includes a piping system 910, a material forming device 920, a fluid drive system 930, a damping system 940, an adapter 950, and a tip 960.

[0056] In various embodiments, the piping system 910 includes a fluid conduit 912, a fluid inlet 914, and a fitting 916. The fluid conduit 912 is configured to direct hot air from the fluid inlet 914 through the fluid conduit 912 and out of the tip 960. In this regard, according to various embodiments, when the material forming apparatus 920 is condensing / conforming previously deposited material (e.g., after step 102, step 106, and / or step 108), the hot air can soften the previously deposited material and facilitate bonding with the previous layer. The fitting 916 is configured to couple to a heating system of a typical CNC machine. In this regard, the fitting 916 may be configured to removably couple to a heating system (e.g., fitting 918 of FIG. 9A of the hybrid CNC machining / 3D printing device 201 of FIG. 2A, the hybrid CNC machining / 3D printing device 203 of FIG. 2D, or the 3D printing device 211 of FIG. 2E).

[0057] In various embodiments, the material forming device 920 comprises a sphere 922. While illustrated as comprising a sphere, the disclosure is not limited thereto. For example, the material forming device 920 can have various shapes, such as a hemispherical shape, a cylindrical shape, etc. The material forming device 920 extends at least partially through an outlet 962 of the tip 960. According to various embodiments, the material forming device 920 may be coupled to a strut 942 of a damping system 940. The damping system 940 is configured to facilitate damping of the material forming device 920 during operation of the condensation / conforming tool 250. For example, the damping system 940 allows the material forming device 920 to move axially along a central axis of the strut 942. In this regard, various According to certain embodiments, the damping system can compensate for geometric inconsistencies when pressure is applied and / or prevent damage to the respective parts or hybrid CNC machining / 3D printing device 201 of Figure 2A, hybrid CNC machining / 3D printing device 203 of Figure 2D, and / or 3D printing device 211 of Figure 2E during use. In various embodiments, the damping system 940 can include a gas shock strut system, a spring loaded system, or the like.

[0058] In various embodiments, fluid drive system 930 may include a fan 932 mounted on a spindle 934. In various embodiments, spindle 934 is configured to operably couple to spindle 205 of hybrid CNC machining / 3D printing device 201 of FIG. 2A , hybrid CNC machining / 3D printing device 203 of FIG. 2D , and / or 3D printing device 211 of FIG. 2E . In this regard, spindle 934 and spindle 205 may be configured to rotate together relative to frame 204 of FIG. 2A in response to condensation / conforming tool 250 being coupled to spindle 205 of hybrid CNC machining / 3D printing device 201.

[0059] In various embodiments, the fan 932 is configured to drive hot air from the fluid conduit 912 of the piping system 910. In this regard, the fan 932 may rotate about an axis defined by a spindle 934 and push air from the fluid conduit 912, such as by suction. In various embodiments, the fan 932 may further pressurize the material forming apparatus 920 according to various embodiments. In this regard, the fluid drive system 930 may be a dual-purpose system (i.e., by drawing hot air from the fluid conduit 912 of the piping system 910, it may provide additional pressure to more efficiently conform the deposited material and / or soften the deposited material).

[0060] In various embodiments, fluid drive system 930 includes bearings 936. Bearings 936 can facilitate efficient rotation of spindle 934 and fan 932. In various embodiments, any type of bearing can be utilized for bearing 936, such as a roller bearing, a ball bearing, or the like. The disclosure is not limited in this regard. Fan 932 is configured to rotate relative to housing 970. In this regard, condensation / adaptation tool 250 may further include a disengagement pin 972 coupled to housing 970 configured to keep housing 970 stationary during operation of fluid drive system 930. For example, disengagement pin 972 is configured to engage a socket in a tool holder of hybrid CNC machining / 3D printing device 201 of FIG. 2A , hybrid CNC machining / 3D printing device 203 of FIG. 2D , and / or 3D printing device 211 of FIG. 2E , as described further herein.

[0061] In various embodiments, the adapter 950 is coupled to a radially outer surface of the spindle 934. While the adapter 950 is shown as a separate component, according to various embodiments, it may be integral with the spindle 934. The adapter 950 is configured to operably couple a tool holder of the hybrid CNC machining / 3D printing device 201 of FIG. 2A to the spindle 934. In this regard, according to various embodiments, the tool holder may be operably coupled to the controller 208 of FIG. 2A , which may be configured to drive the spindle 934 via movement of the tool holder.

[0062] In various embodiments, the condensation / fit tool 250 is adaptable to a typical CNC machining tool holder. In this regard, the condensation / fit tool 250 can be retrofitted to any existing CNC machining tool drive system and operated as described herein. The condensation / fit tool 250 can facilitate smoother bonding between various layers during the manufacture of a 3D printed product (e.g., during method 100 of FIG. 1). As further described, the condensation / adaptation tool 250 may be replaced with subtractive components 240 of the CNC machine or hybrid CNC machining / 3D printing device 201 of FIG. 2A and / or hybrid CNC machining / 3D printing device 203 of FIG. 2D.

[0063] 10, a side view of a condensation / conform tool 1000 is shown in accordance with various embodiments. In various embodiments, the condensation / conform tool 1000 may include the piping system 910 of FIGS. 9A-9C, the material forming device 920, the fluid drive system 1030, the damping system 940, the adapter 950, and the nozzle 1060.

[0064] In various embodiments, the fluid drive system 1030 may include a turbine 1032. In various embodiments, the turbine 1032 may include a Pelton turbine design (i.e., the turbine 1032 may be configured to rotate independently of the spindle 934). For example, the turbine 1032, according to various embodiments, may be configured to rotate in response to compressed air blown against buckets of each turbine blade within the turbine 1032.

[0065] In various embodiments, the nozzle 1060 includes a plurality of fluid outlets 1062 disposed proximate to the material formation apparatus 920. In various embodiments, the tip 960 may also include a plurality of fluid outlets 1062. The plurality of fluid outlets 1062 may be disposed radially outward from the material formation apparatus 920 and directed along an axis defined by the spindle 934. In this regard, hot air may be directed toward the material being condensed or adapted according to step 103 of the method 100 of FIG.

[0066] 11A-11H, various embodiments of the condensation / fit tool 250 are shown installed in the tool holder 1002 of the hybrid CNC machining / 3D printing device 201 (FIGS. 11A-11E) and the condensation / fit tool 250 being replaced with the subtractive component 240 (FIGS. 11F-11H). In various embodiments, the hybrid CNC machining / 3D printing device 201 includes an arm 260. According to various embodiments, the arm 260 is configured to grab a respective tool (e.g., the subtractive component 240 or the condensation / fit tool 250) from a tool storage area, rotate the tool to the spindle taper 270, and couple the tool to the spindle taper 270 or the spindle 205 of FIG. 2A. The arm 260 is in operative communication with the controller 208 of FIG. 2A. The spindle taper 270 may include a socket configured to receive the spindle of the condensation / fit tool 250. In this regard, the spindle taper 270 may include a drive motor configured to rotate the spindle, as described further herein.

[0067] 12, a schematic block diagram of the manufacturing system 200 of FIG. 2 is shown, according to various embodiments. The manufacturing system 200 includes a controller 208 in electrical communication with a frame 204, a spindle 205, a drive motor 310 for each extrusion unit (e.g., extrusion units 210, 220, 230) of FIG. 2A, a heating system 340, 540 for each extrusion unit (e.g., extrusion units 210, 220, 230) of FIG. 2A, an actuator 212 for each extrusion unit (e.g., extrusion units 210, 220, 230) of FIG. 2A, a power source 804, and / or a temperature sensor 560 for each extrusion unit (e.g., extrusion units 210, 220, 230) of FIG. 2A. In various embodiments, a CNC tool (e.g., ablation component 240, condensation / conformation tool 250, etc.) may be operable by the controller via the spindle 205 of FIG. 2A. In this regard, the controller 208 may be configured to command the spindle 205 to rotate, which may in turn rotate the spindles of the respective CNC tools (e.g., subtractive component 240, condensation / conformal tool 250, etc.). As used herein, the hybrid CNC machining / 3D printing system of FIG. Although described with respect to printing device 201, system 200 is also applicable to hybrid CNC machining / 3D printing device 203 of FIG. 2D and 3D printing device 211 of FIG. 2E, except as otherwise specified herein.

[0068] In various embodiments, the controller 208 may be integrated into a microcontroller disposed within the hybrid CNC machining / 3D printing device 201 of FIG. 2A . In various embodiments, the controller 208 may be configured as a central network element or hub for accessing the various systems and components of the manufacturing system 200. The controller 208 may comprise a network, computer-based system, and / or software component configured to provide an access point to the various systems and components of the manufacturing system 200. In various embodiments, the controller 208 may comprise a processor. In various embodiments, the controller 208 may be implemented in a single processor. In various embodiments, the controller 208 may be implemented as or include one or more processors and / or one or more tangible, non-transitory memories and may be capable of implementing logic. Each processor may be a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof. Controller 208 may comprise a processor configured to perform various logical operations in response to execution of instructions, for example, instructions stored on a non-transitory tangible computer-readable medium configured to communicate with controller 208. In various embodiments, power source 804 may include a battery, an electrical outlet, or the like.

[0069] The system program instructions and / or controller instructions may be loaded onto a non-transitory, tangible computer-readable medium that stores instructions that, in response to execution by the controller, cause the controller to perform various operations. The term "non-transitory" should be understood to exclude only propagating transitory signals, per se, from the claims, and does not disclaim all standard computer-readable media other than propagating transitory signals, per se. In other words, the meaning of the terms "non-transitory computer-readable medium" and "non-transitory computer-readable storage medium" should be interpreted to exclude only transitory computer-readable media of the type recognized in In Re Nuijten as outside the scope of patentable subject matter under 35 U.S.C. § 101.

[0070] In various embodiments, the heating system 340, 540 includes at least one hot air blower (e.g., hot air blower 342, 542, 552) and at least one temperature sensor 802. In various embodiments, the heating system 340, 540 may include a temperature sensor for each hot air blower. In this regard, the output temperature of each hot air blower may be monitored by the controller 208, and the temperature of each hot air blower may be adjusted in response to the monitoring by the controller 208.

[0071] In various embodiments, controller 208 may be configured to turn on a CNC tool (e.g., subtractive component 240, condense / fit tool 250, etc.) via spindle 205 disposed within frame 204 of FIG. 2A in response to completing a lay-up step of method 100 of FIG. 1 (e.g., step 102 of method 100). In various embodiments, controller 208 may be configured to transition from a first CNC tool to a second CNC tool (e.g., from condense / fit tool 250 to subtractive component 240, or vice versa). In this regard, according to various embodiments, in response to completing step 103 of method 100 of FIG. 1, controller 208 may replace condense / fit tool 250 with subtractive component 240, as shown in FIGS. 11A-11H. In this regard, subtractive When a step begins in method 100 (e.g., step 104), subtractive component 240 may be turned on and spindle 205 may be translated based on the desired specifications of each 3D component based on what needs to be removed from the rough shape generated in the build step (e.g., step 102 of method 100 of FIG. 1).

[0072] In various embodiments, the drive motor 310 for each extrusion unit (e.g., the first extrusion unit 210, the second extrusion unit 220, and / or the third extrusion unit 230 of FIG. 2A ) may be in electronic or wireless communication with the controller 208. In this regard, the respective drive motors 310 may be turned on based on which step of the method 100 the manufacturing system 200 is in. For example, during the deposition step (e.g., step 102), the drive motor 310 of the first extrusion unit 210 may be turned on, and the spindle 205 may be translated based on the desired rough shape of the respective 3D component to be printed. Similarly, during the deposition step (e.g., steps 102, 106, 108), the drive motor 310 of the second extrusion unit 220 or the third extrusion unit 230 may be turned on, and the spindle 205 may be translated based on the desired deposition position for the respective support material or finer material.

[0073] In various embodiments, the controller 208 is configured to translate the actuators 212 of each extrusion unit (e.g., the first extrusion unit 210, the second extrusion unit 220, and / or the third extrusion unit 230). In this regard, according to various embodiments, during a layering or deposition step (e.g., steps 102, 106, 108 of the method 100 of FIG. 1), the controller 208 can instruct the actuators 212 of each extrusion unit (e.g., the extrusion units 210, 220, 230 of FIG. 2A) to translate based on the desired specifications of the respective 3D component being manufactured.

[0074] While the principles of the present disclosure are illustrated in various embodiments, many modifications of the construction, arrangement, proportions, elements, materials, and components actually used are specifically adapted to particular environments and operating requirements and may be used without departing from the principles and scope of the present disclosure. These and other changes or modifications are intended to be included within the scope of the present disclosure.

[0075] The present disclosure has been described with reference to various embodiments. However, those skilled in the art will understand that various modifications and changes can be made without departing from the scope of the present disclosure. Accordingly, the specification is to be regarded in an illustrative rather than a limiting sense, and all such modifications are intended to be included within the scope of the present disclosure. Similarly, benefits, other advantages, and solutions to problems have been described above with respect to various embodiments. However, benefits, advantages, solutions to problems, and any element that may cause or make any benefit, advantage, or solution more noticeable should not be construed as a critical, necessary, or essential feature or element.

[0076] As used herein, the terms "comprises," "comprising," or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. As used herein, the terms "coupled," "coupled" or any other variations thereof are intended to cover physical, electrical, magnetic, optical, communicative, functional, and / or any other connection. When language similar to "at least one of A, B, or C" or "at least one of A, B, and C" is used in the specification or claims, this phrase is intended to mean any of the following: (1) at least one of A; (2) at least one of B; (3) at least one of C; (4) at least one of A and at least one of B. (5) at least one of B and at least one of C; (6) at least one of A and at least one of C; or (7) at least one of A, at least one of B, and at least one of C.

Claims

1. a first spindle taper adaptable to be operatively coupled to a spindle of a computer numerically controlled (CNC) machine; a nozzle defining a tip; a housing coupled to the nozzle; a fluid drive system disposed between the first spindle taper and the nozzle, the fluid drive system configured to drive fluid toward a fluid outlet disposed proximate to the tip of the nozzle, the fluid drive system comprising a turbine configured to rotate relative to the housing; and a material forming device disposed adjacent to the tip of the nozzle; Equipped with A condensation device for use in a 3D printing system.

2. and a piping system configured to couple to a heating system of the CNC machine. The condensation device of claim 1 .

3. the piping system is configured to receive hot air through the CNC machine during operation of the condensing device. The condensation device of claim 2 .

4. further comprising a damping system coupled to the material forming device. The condensation device of claim 1 .

5. the damping system comprises a strut; The condensation device of claim 4 .

6. A drive motor; an auger coupled to the drive motor; a housing assembly, the auger disposed within the housing assembly and configured to translate material to be deposited through the housing assembly; a hopper in fluid communication with the housing assembly; a heating system coupled to the housing assembly, the heating system heating the deposited layer prior to depositing a second layer; At least one of a mount or an actuator, wherein the at least one of the mount or the at least one of the actuators can be removably coupled to a computer numerically controlled (CNC) machining device; Equipped with the heating system further comprising a first hot air blower disposed radially outward of the housing assembly; the heating system further comprising a second hot air blower disposed radially outward of the housing assembly; An extrusion device for use in a 3D printing system.

7. the heating system further comprising a hot air blower in fluid communication with the hot air duct; The extrusion device of claim 6.

8. further comprising a nozzle in fluid communication with the housing assembly. The extrusion device of claim 7.

9. Further comprising an outlet of the hot air duct, the outlet is located radially outward of the nozzle; 9. The extrusion device of claim 8.

10. a spool feeder system configured to feed a filament into the housing assembly and across the material to be deposited; The extrusion device of claim 6 .

11. the spool feeder system comprising a spool, a second drive motor, and a shaft; the second drive motor is configured to drive the shaft; the spool is configured to rotate in response to the shaft being driven; The extrusion device of claim 10.

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