System and method for dynamically controlling a thermosetting three-dimensional printer having multiple extruders

Abstract

This system provides a computer system for dynamically controlling printing parameters within a three-dimensional printer. [Solution] A computer system for dynamically controlling printing parameters within a 3D printer receives indicators for printing a target object by the 3D printer. The computer system accesses a material attribute dataset, which describes the different material properties of multiple thermosetting materials or mixtures thereof. Based on the material attribute dataset, the computer system selects one or more thermosetting materials from a set of multiple thermosetting materials for each of the multiple extruders to form an extruded body and determines the extrusion configuration of the selected one or more thermosetting materials. The computer system then generates commands for the multiple extruders of the thermosetting 3D 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 number W911NF-17-2-0227 awarded by the U.S. Army (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 and priority of U.S. Provisional Patent Application No. 63 / 292,753, filed on December 22, 2021, entitled "SYSTEM AND METHOD FOR DYNAMICALLY CONTROLLING THERMOSET THREE - DIMENSIONAL PRINTER WITH MULTIPLE EXTRUDERS", which is hereby incorporated by reference in its entirety.

Background Art

[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 within a thermoset three - dimensional printer based on 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 manufacture a wide variety of objects from common computer - aided design (CAD) files. In 3D printing, a composition is provided in successive layers of material to build a structure. These layers can be generated from, for example, liquids, powders, paper, or sheet materials.

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

[0006] There are many ways to improve 3D printing. These improvements can include faster printing, higher resolution printing, and more durable final products, among many other desired outcomes. [Overview of the Initiative]

[0007] A computer system for dynamically controlling printing parameters within a 3D printer comprises one or more processors and one or more computer-readable media storing executable instructions, the computer system configured to perform various actions when executed by one or more processors. For example, the computer system receives an index for printing a target object by the 3D printer. The computer system accesses a material attribute dataset, which describes the different material properties of multiple thermosetting materials or mixtures thereof. Based on the material attribute dataset, the computer system selects one or more thermosetting materials from a plurality of thermosetting materials for each of the multiple extruders to form an extruded body and determines the extrusion configuration of the selected one or more thermosetting materials. The computer system then generates commands to cause the multiple extruders of the thermosetting 3D printer to implement the multiple extruder configurations while printing the target object.

[0008] A three-dimensional printer (3D) may comprise multiple extruders, each configured to extrude different extruded bodies. A 3D printer may also comprise one or more processors and one or more computer-readable media containing executable instructions that, when executed by one or more processors, configure the 3D printer to perform various actions. For example, a 3D printer may receive commands to print a target object. Based on the commands, for each of the multiple extruders, the 3D printer may select one or more thermosetting materials from a group of thermosetting materials, 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.

[0009] A computer implementation method running on one or more processors to dynamically control a thermosetting 3D printer to produce desired material attributes includes receiving an indicator for printing a target object by the 3D printer. The method also includes accessing a material attribute dataset, which describes the different material properties of multiple thermosetting materials being printed. Based on the material attribute dataset, for each of multiple extruders, the method includes selecting one or more thermosetting materials from a plurality of thermosetting materials for each of the multiple extruders to form an extruded body, determining the extrusion configuration of one or more thermosetting materials, and generating commands to cause the multiple extruders of the thermosetting 3D printer to implement the specific extrusion configuration while printing the target object.

[0010] Additional features and advantages of exemplary implementations of the present invention are described in the following description and may be partially apparent from the description or may be known through practice of such exemplary implementations. These features and advantages may be realized and obtained by the fixtures and combinations specifically indicated in the appended claims. These and other features may be more fully apparent from the following description and the appended claims or may be known through practice of exemplary implementations as set forth below.

[0011] To illustrate the manner in which the above-described and other advantages and features of the present invention can be obtained, a more detailed explanation of the principle briefly described above is made by reference to the specific embodiments illustrated in the accompanying drawings. It is understood that these drawings depict only typical embodiments of the invention and are therefore not intended to limit its scope. The invention is described and explained below with additional specificity and detail through the use of the accompanying drawings described below. [Brief explanation of the drawing]

[0012] [Figure 1] This document illustrates a system for thermosetting 3D printing. [Figure 2] This document illustrates a schematic diagram of a computer system for thermosetting 3D printing. [Figure 3] The side views of different bead sizes are illustrated with examples. [Figure 4A] Different extruder and thermosetting material feeding configurations are illustrated as examples. [Figure 4B] Different extruder and thermosetting material feeding configurations are illustrated as examples. [Figure 4C] Different extruder and thermosetting material feeding configurations are illustrated as examples. [Figure 5] A flowchart of Method 500 for dynamically controlling a thermosetting 3D printer using multiple extruders is drawn. [Modes for carrying out the invention]

[0013] The present invention relates to systems, methods, and apparatus for dynamically controlling multiple extruders within a thermosetting three-dimensional (3D) printer. The systems, methods, and apparatus operate through the deposition of co-reactive materials while producing a target object. As used herein, “target object” may refer to a physical object or a portion of a complete physical object that is additionally produced by the systems, methods, and / or apparatus described herein. Additionally, as used herein, co-reactive materials include thermosetting materials.

[0014] Additive manufacturing using co-reactive components offers several advantages compared to alternative additive manufacturing methods. As used herein, “additive manufacturing” refers to the use of computer-aided design (e.g., through user-generated files or 3D object scanners) to deposit material layer by layer in an additive manufacturing apparatus in a precise geometric shape. Because materials forming continuous layers can be co-reacted to create covalent bonds between layers, additive manufacturing using co-reactive components can produce stronger parts. Furthermore, because the components have low viscosity when mixed, higher filler content can be used. Using higher filler content can modify the mechanical and / or electrical properties of the material and the constructed target object. Co-reactive components can extend the range of chemicals used in additively manufactured parts, providing improved properties such as solvent resistance and heat resistance.

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

[0016] For the purposes of the following detailed description, it should be understood that the present invention may take various alternative modifications and sequences of steps, unless expressly otherwise specified. Furthermore, except for any example of operation, or where otherwise indicated, all numbers representing the quantities of components used in the specification and claims should be understood in all examples as being modified by the term “approximately.” Thus, unless shown to be contrary, the numerical parameters described 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 equivalent view to the claims, each numerical parameter should be interpreted by applying the usual rounding technique in light of at least the number of significant digits reported. Although the numerical ranges and parameters describing the broad scope of the present invention are approximations, the numbers described in specific examples are reported as accurately as possible. However, any number inherently contains a certain error that inevitably arises from the standard deviation observed in their respective test measurements.

[0017] Furthermore, it should be understood that any numerical range described herein is intended to include all subranges contained therein. For example, the range "1 to 10" is intended to have all subranges between (and including) the stated minimum value of 1 and the stated maximum value of 10, i.e., the minimum value equal to or greater than 1 and the maximum value equal to or less than 10.

[0018] The use of the singular form includes the plural form unless otherwise specifically stated, and the plural form includes the singular form. In addition, while "and / or" may be used explicitly in certain examples, the use of "or" means "and / or" unless otherwise specifically stated.

[0019] The term "polymer" includes prepolymers, homopolymers, copolymers, and oligomers.

[0020] In addition, unless otherwise indicated, numerical values representing amounts, constituent materials, distances, or other measurements used in this specification and the claims are to be understood as being optionally modified by the term "about" or its synonyms. When the terms "about," "approximately," "substantially," or the like are used in conjunction with a recited amount, value, or condition, it can 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% from the recited amount, value, or condition.

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

[0022] Deposition and like terms refer to the application of a printing material that contains co-reacting, or co-reaction compositions and / or their reactive components, onto a substrate (for the first portion of the object) or onto a previously deposited portion or layer of the object. Each co-reactive component can include monomers, prepolymers, adducts, polymers, and / or cross-linking agents that can chemically react with the constituent materials of the other co-reactive components.

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

[0024] Alternatively, two co-reactive components can be deposited separately from each other and react upon deposition to form a portion of an object. For example, two co-reactive components can be deposited separately, such as by using an inkjet printing system, such that the two reactive components are deposited in sufficient proximity to overlap with each other and / or adjacent to each other so that they can react to form a portion of the object. As another example, in an extrudate, rather than being homogeneous, the cross-sectional profile of the extrudate can be non-uniform such that different portions of the cross-sectional profile can have one of the two co-reactive components and / or can contain mixtures of the two co-reactive components in different molar ratios and / or equivalent ratios.

[0025] Furthermore, different parts of an object may be formed using different proportions of two co-reactive components, so that different parts of the object may be characterized by different material properties throughout the 3D printed object. For example, some parts of the object may be rigid, while other parts 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 embodiments, material properties may refer to the rigidity of a cured thermosetting material after it has been extruded to produce 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 co-reactive components can be adjusted to control the flow of the co-reactive components and / or co-reactive compositions so that the deposited portion and / or object achieves and maintains the desired structural integrity after deposition. The viscosity of co-reactive components can be adjusted by including a solvent, or the co-reactive components may be substantially solvent-free or completely solvent-free. The viscosity of co-reactive components can be adjusted by including a filler, or the co-reactive components may be substantially filler-free or completely filler-free. The viscosity of co-reactive components can be adjusted by using components with lower or higher molecular weights. For example, co-reactive components may include prepolymers, monomers, or combinations of prepolymers and monomers. The viscosity of co-reactive components can be adjusted by changing the deposition temperature. Co-reactive components may have viscosity and temperature profiles that can be adjusted for the specific deposition method used, such as mixing before deposition and / or inkjet printing. Viscosity may be influenced by the composition of the co-reactive components themselves and / or can be controlled by the inclusion of rheological modifiers as described herein.

[0027] Viscosity and / or reaction rate may be desirable so that the composition retains its intended shape after the deposition of co-reactive components. For example, if the viscosity is too low and / or the reaction rate is too slow, the deposited composition may flow in a way that impairs 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 impaired.

[0028] Referring here to the figure, Figure 1 illustrates a system for 3D printing using co-reactive components. The system depicted comprises a 3D printer 100 communicating 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 a cloud computing environment), or otherwise integrated with the 3D printer 100. As used herein, “3D printer” refers to any device that enables additive manufacturing using computer-generated data files. Such computer-generated data files are referred to herein as “CAD files.”

[0029] The 3D printer 100 is depicted together with the target object 120 in a wedge shape. The wedge shape is constructed by the 3D printer 100 using a co-reactive component, at least in part. The 3D printer 100 also comprises a dispenser 130 attached to a moving mechanism 140. As used herein, “dispenser” may comprise one or more extruders, one or more dynamic nozzles, one or more static nozzles, one or more spraying 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 moving mechanism 140 is described to include a dispenser mounted in a track 142 that is movable along the arm in the X-axis direction, and another set of tracks 144 on which the arm is movable in the Y-axis direction. However, it should be understood that this configuration is provided for illustrative and explanatory purposes only. In additional or alternative configurations, the moving mechanism 140 may include any system that can control 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] Furthermore, the 3D printer 100 is connected to one or more containers 152(a-e) of the co-reactive components. In the embodiment described, the co-reactive components are accessed through a selectable manifold 150 that allows the user to select the desired container 152(a-e) from which to extract the co-reactive components. However, it will be understood that the system described for 3D printing is merely illustrative. For example, in alternative cases, the system may have different configurations of the co-reactive components and the selectable manifold 150, or it may not have the selectable manifold 150 at all.

[0032] Figure 2 illustrates a schematic diagram of a computer system for thermosetting 3D printing. The computer system 110 is shown as communicating with the 3D printer 100. Additionally, various modules or units of the 3D printing design software 200 are depicted as being executed by the computer system 110. In particular, the 3D printing design software 200 is depicted as comprising a tool path generation unit 240, a flow rate processing unit 242, a dispenser control unit 244, and a material database 246 (also referred to herein as the “material attribute database” and “material attribute dataset”).

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

[0034] As used herein, “module” includes computer executable code and / or computer hardware that perform a particular function. Those skilled in the art will understand that distinctions between different modules are at least partially arbitrary, and that modules may be combined and divided in different ways and still fall within the scope of this disclosure. Therefore, descriptions of components as “modules” are provided for clarification and descriptive purposes only and should not be construed to indicate 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,” and “virtual machine” may also be used similarly.

[0035] The computer system 110 also comprises one or more processors 210 and one or more computer storage media 220 storing executable instructions that, when executed by one or more processors 210, configure the computer system 110 to perform various actions. For example, the computer system 110 may receive an indicator to cause the 3D printer 100 to print layers. As used herein, “indicator” includes any form of input received by the computer system 110. For example, an indicator may include 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 reception of a data file, or any other form of input that causes the computer system 110 to perform further actions.

[0036] When the computer system 110 receives an indicator for printing a layer of the target object 120, the tool path generation unit 240 generates a tool path for additionally manufacturing the target object 120. As used herein, “tool path” refers to the path of the dispenser 130 in manufacturing the target object 120. Additionally, “tool path” may also refer to the speed and / or flow rate of the dispenser 130 in manufacturing the target object 120. The tool path generation unit 240 generates a tool path such that the co-reactive material is dispensed from the dispenser 130 along the path that produces the target object 120 at a certain speed.

[0037] In some situations, the tooling pathway may require the dispenser 130 to layer the co-reactive materials in multiple layers on top of each other. The flow rate processing unit 242 calculates a target rate to ensure that the co-reactive materials bond properly between the different layers. Such calculations can be the primary factor in the reaction time of the co-reactive materials, such as layering the materials on top of each other before the lower layers have fully cured. Thus, the generation of the first tooling pathway may be based, at least in part, on a target flow rate. As described 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 contain information about the material attributes of the co-reactive materials in both the cured and uncured states.

[0038] As used herein, “flow rate” includes the rate at which one or more components of the material are dispensed from the dispenser 130. The flow rate may be controllable on a component-by-component basis. 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 co-reactive materials to produce a target object 120.

[0039] The flow rate processing unit 242 may be configured to manipulate the flow rate of the co-reactive material by altering the properties of the co-reactive components within the co-reactive material while creating the target object 120. It will be understood 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 thermosetting composition so that the deposited portion and / or object achieves and maintains 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 solvent-free or completely solvent-free. The viscosity of the co-reactive components may be adjusted by including a filler, or the co-reactive components may be substantially filler-free or completely filler-free. 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 combinations of prepolymers and monomers. The viscosity of the co-reactive components may be adjusted by changing the deposition temperature. Co-reactive components may have viscosity and temperature profiles that can be adjusted for the specific deposition method used, such as pre-deposition and / or pre-inkjet mixing. Viscosity may be influenced by the composition of the co-reactive component itself and / or controlled by the inclusion of rheological modifiers as described herein.

[0040] Viscosity and / or reaction rate may be desirable so that the composition retains its intended shape after the deposition of co-reactive components. For example, if the viscosity is too low and / or the reaction rate is too slow, the deposited composition may flow in a way that impairs 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 impaired.

[0041] For example, the co-reactive components deposited together have viscosities at 25°C and 0.1s 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 deposited together may have a viscosity at 25°C and a viscosity of 50 centipoise (cP) to 50,000 cP, 100 cP to 20,000 cP, or 200 to 10,000 cP over 1,000 s. -1 It may have a shear rate of . 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 actual bead size or layer size dispensed by the dispenser 130 can be controlled by adjusting the viscosity and / or reaction rate. As used herein, “beads” includes layers of material dispensed by the dispenser 130 along the tool path. Similarly, as used herein, “bead size” includes the dimensions of one or more layers being dispensed by the dispenser 130. For example, bead size may include the height of a bead, the radius of a bead, the width of a bead, or any other physical dimension of a bead. It will be understood that although the word “beads” is used herein, the actual layers do not need to be physically similar to conventional bead shapes.

[0043] Additionally or alternatively, the dispenser control unit 244 may adjust the properties of the 3D printer 100 to achieve a desired flow rate. For example, the dispenser control unit 244 may move the dispenser 130 faster or slower to achieve a desired bead size, deposition rate, viscosity, and / or reaction rate. For instance, if the dispenser 130 is dispensing the co-reactive material at a constant rate, and the dispenser control unit 244 moves the dispenser at a faster rate than 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 rate based on a desired flow rate and / or bead size. Thus, 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 a desired flow rate and / or bead size.

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

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

[0046] Returning to controlling the thermosetting 3D printer 100 to produce 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 typically have a single extruder configured to print 3D objects using a single material, and conventional 3D printing software is designed to print 3D objects using a single extruder. Unlike conventional 3D printers, the 3D printer 100 described herein may have two or more extruders. Each extruder is configured to extrude a different material, which may be a specific thermosetting material or a combination of several different thermosetting materials. In some cases, multiple extruders are configured to extrude beads formed by different materials substantially simultaneously and in substantially the same location, such that multiple beads (formed by different materials) react with each other or partially react with each other to form a single bead of the reacting 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 composition of 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, the user can simply input the desired final material properties of the surface of the target object to be printed. In response to the user input, the computer system 110 is configured to determine a specific mixture composition of one or more thermosetting materials in order to achieve the desired final material properties of the surface.

[0048] For example, the computer system 110 is configured based on indicators received from the user (directly or indirectly from the user, another computer program, and / or the 3D printer 100). The indicators include indicators of the desired final material properties of the surface of the target object to be printed. In some configurations, the indicators may be entered directly by the user in the computer system 110 or in the 3D printer 100. In some configurations, the indicators are configured within a thermosetting print data packet, which may be generated by the 3D printing software 220 based on the user's indicators. 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 indices of one or more thermosetting materials (contained in containers 152a-152e) that are available to the thermosetting 3D printer. These indices may also be received directly or indirectly from the user, another computer program, barcodes on containers 152a-152e, integrated circuits within containers 152a-152e, and / or the 3D printer 100. In response to the indices of the desired final material properties of the surface of the target object and the indices of one or more thermosetting materials, the 3D printing design software 200 accesses a material attribute dataset stored in the material attribute database 246. The material attribute dataset describes the different material properties that result from different mixture configurations of one or more thermosetting materials. Based on the information in the material attribute database 246, the 3D printing design software 200 determines a specific mixture configuration of one or more thermosetting materials to achieve the desired final material properties of the surface, and generates a command to cause the thermosetting 3D printer 100 to implement the specific mixture configuration of one or more thermosetting materials when printing the surface.

[0050] In some configurations, a particular mixture configuration includes a specific 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 a specific 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 side views of different bead sizes. In the depicted embodiment, the first bead size 310 is the 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, and so on. Based on the determined ratio of one or more thermosetting materials and / or 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 against the first thermosetting material, and the second bead size 320 is implemented against the second thermosetting material among the one or more thermosetting materials.

[0052] Figures 4A to 4C depict schematic diagrams of a 3D printer 100 comprising multiple extruders 450(a, b, c) and 460(a, b, c). In the embodiments depicted, 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 will be discussed in more detail below, the nozzles may be interchangeable so that each of the multiple extruders 450(a, b, c) and 460(a, b, c) is associated with a separate nozzle which may contain specific properties relevant to the extrusion of thermosetting materials. In some configurations, the 3D printer 100 can be configured so that each of the multiple extruders 450(a, b, c) and 460(a, b, c) extrudes a different extruded body. Additionally or alternatively, the 3D printer 100 can be configured so that at least a portion of the multiple extruders 450(a, b, c) and 460(a, b, c) extrude the same extruded body.

[0053] The computer system 110 can receive an indicator for printing the target object 120 by the 3D printer 100. In Figures 4A to 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) so that multiple different extruders are used to produce the target object 120.

[0054] When the computer system 110 receives an index for printing a target object 120, the index may include a digital file describing the physical geometric shape of the target object, including its dimensions. As described above, the digital file may further indicate the desired final material properties of the surface of the target object to be printed. In response, the computer system 110 may access a material attribute dataset 246. As used herein, “material attribute dataset” includes information about various thermosetting materials, in particular, different material properties resulting from mixing various thermosetting materials at various ratios and rates. For example, different material properties may include, at least, the fluidity or gel properties of multiple thermosetting materials in different ratios before co-reaction, or mixtures thereof. Different material properties may additionally or alternatively include, at least, hardness, flexibility, tensile strength, color, temperature resistance, sound dampening, expansion, flame retardancy, shatter resistance, expandability, conductivity of multiple thermosetting materials, or mixtures thereof, in different ratios after co-reaction.

[0055] In some cases, the indicators for printing the target object 120 may not include any specified desired final material properties; 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 overhangs in the physical geometry of the target object 120. In response to identifying the overhangs, the computer system may automatically calculate that one or more surfaces of the target object 120 must have a certain level of stiffness to support the overhangs. The determination of stiffness may be done by accessing lookup tables in the material attribute database 246 and may also depend on the type of thermosetting material used to create the overhangs. For example, the material attribute database 246 may provide lookup tables or formulas for calculating the amount of stiffness and structural support provided by a given material among 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 necessary to maintain the desired overhangs. The above explanation relating to overhand is merely illustrative, and it will be understood that the same lookup table and the calculation of the desired final material properties can be calculated by the computer system 110 in response to various different physical geometric shapes.

[0056] Based on a material attribute dataset, for each of the multiple extruders 450(a,b) and 460(a,b), the computer system 110 selects one or more thermosetting materials from a plurality of thermosetting materials (e.g., one or more containers 152(a-e)) for each of the multiple extruders to form an extruded molded body. Additionally, for each of the multiple extruders 450(a,b) and 460(a,b), the 3D printer 100 determines the extrusion configuration of the selected one or more thermosetting materials. The act of selecting one or more thermosetting materials for each of the multiple extruders 450(a,b) and 460(a,b) may include the computer system 110 transmitting commands to the manifold 150 to open and close specific channels between one or more containers 152(a-e) and each of the multiple extruders 450(a,b) and 460(a,b). For example, in Figure 4A, extruder 450a is supplied by feed sources 410a and 420a, while extruder 460a is supplied by feed sources 430a and 440a. In contrast, in Figure 4B, extruder 450b is supplied by feed sources 410b and 420b, while extruder 460b is supplied both by feed source 420b and separately by feed source 430b. As used herein, “feed source” refers to containers 152(a-e) and container 250(a,b). Thus, in some configurations, each of the multiple extruders is coupled to a separate set of material feed 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 feed sources 410C, 420C, and 430C.

[0057] As used herein, “extrusion configuration” refers to the variables applied to the extrusion of material from a 3D printer. For example, the act of determining the extrusion configuration for each of a plurality of extruders 450(a,b) and 460(a,b) may include determining at least one of the thermosetting material to be extruded, the extrusion rate, the extrusion timing, or the extrusion path. Additionally or alternatively, determining the extrusion configuration for each of the plurality of extruders 450(a,b) and 460(a,b) may include selecting a specific nozzle to pair with a particular extruder of the plurality of extruders 450(a,b) and 460(a,b), or adjusting the 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. Extrusion properties include the extruder orifice dimensions, the extruder material composition, the extruder's maximum and minimum extrusion speeds, the nozzle(s) associated with the extruder, and various other similar properties. The computer system 110 can further determine the extrusion configuration of each of several extruders by configuring a first extruder to extrude a material having a first set of material properties, and 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 understood that, in practice, more than two materials may be available through one or more extruders. Furthermore, 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 received by the 3D printer 100 to print the target object 120. In particular, the computer system 110 may generate commands to cause multiple extruders 450(a, b) and 460(a, b) of the thermosetting 3D printer 100 to implement extrusion configurations while the target object 120 is being printed. In the embodiment described, the target object 120 has multiple parts having different material properties (indicated by tool paths 472(a, b, c), 474(a, b, c), 476(a, b, c), and 478(a, b, c)). For each of the multiple parts, the computer system 110 selects one or more thermosetting materials from a plurality of thermosetting materials to form an extruded body, selects one of the plurality of extruders, and determines the selected extruder and a specific extrusion configuration for the extruded body.

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

[0060] For example, in Figure 4A, extruder 450a extrudes along tool path 472a, and then extruder 460a extrudes along the directly adjacent tool path 474a. In at least one embodiment, the two extruders 450a and 460a extrude simultaneously so that two tool paths 472a and 474a are extruded at the same time. Additionally or alternatively, extruders 450a and 460a may extrude tool paths 476a and 478a consecutively. The tool path generation unit 240 may utilize the material attribute database 246 when calculating whether tool paths should be extruded consecutively, simultaneously, or as a mixture of several of these. For example, the tool path generation unit 240 may be a primary factor in the curing time of selected thermosetting materials to ensure that tool paths 472(a, b, c), 474(a, b, c), 476(a, b, c), and 478(a, b, c) are properly joined together. For example, materials that harden relatively quickly may need to be extruded simultaneously to ensure proper bonding occurs between 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 the volumetric mixing ratio of one or more selected thermosetting materials for each of the multiple sections indicated 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 a command to supply the selected one or more selected thermosetting materials to the selected extruder at the determined volumetric mixing ratio.

[0062] In some configurations, extruders (e.g., 450a, 450b, 450c, 460a, 460b, 460c) may utilize a purge step when switching to a new material, finishing a tool path, and / or starting a tool path. For example, if a particular extruder (e.g., 450a) is switching to a new material, it may first purge any previous material that may still be contained within extruder 450a. For example, a material database 246 may contain purge entries for each material indicating 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 extruder 450a. Extruder 450a can 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. Next, the extruder 450a is prepared to extrude the new material without contamination from the previous material.

[0063] Alternatively, in some configurations, purging the extruder 450a may involve physically removing the extruder 450a from the 3D printer 100 and replacing it with another extruder. For example, in some configurations, certain materials may harden within the extruder, preventing the extruder 450a from extruding any additional material. In some cases, the extruder may need to be purged or replaced even to continue extruding the same previous material. As with the above, the material database 246 may include information indicating whether a new extruder is needed after a particular material has been used. For example, the material database 246 may indicate how quickly a material hardens. For example, if the extruder 450 has been idle for longer 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 locations of each of the extruders (e.g., 450a, 450b, 450c, 460a, 460b, 460c) relative to one another. For example, the computer system 110 may track the locations of extruders 450a and 450b while the target object 120 is being printed. In some cases, only one extruder is used to extrude the material at a time. Therefore, when a second extruder 460a is needed to extrude the material, the computer system 110 can quickly calculate the 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 it in order to continue printing the target object 120.

[0065] Figure 5 illustrates a flowchart of method 500 for dynamically controlling a thermosetting three-dimensional printer using multiple extruders. Method 500 includes step 510 of receiving an indicator for a target object 512. Step 510 may include receiving an indicator for printing the target object by the three-dimensional printer. For example, as described and illustrated with respect to Figures 1 and 2, a computer system 110 receives an instruction to generate a target object 120.

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

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

[0068] Furthermore, method 500 includes act 540, which generates a command to cause multiple extruders of a thermosetting 3D printer to implement multiple mixture configurations. Act 530 may include generating a command to cause multiple extruders of a thermosetting 3D printer to implement multiple extruder configurations while printing a target object. For example, as shown in Figures 1 to 4C, the 3D printer 100 can print a target object 120 in response to a command from a computer system 110.

[0069] While the subject matter is described using language specific to structural features and / or methodological actions, it should be understood that the subject matter as defined in the attached claims is not necessarily limited to the described features or actions, or the order of the described actions, described above. Rather, the described features and actions are disclosed as exemplary forms that implement the claims.

[0070] The present invention may comprise or utilize a dedicated or general-purpose computer system, including, for example, one or more processors and system memory, computer hardware, as will be discussed in more detail below. Embodiments within the scope of the present invention also include physical and other computer-readable media for transporting or storing computer-executable instructions and / or data structures. Such computer-readable media may be any available media accessible by a general-purpose or dedicated computer system. A computer-readable medium that stores computer-executable instructions and / or data structures is a computer storage medium. A computer-readable medium that transports computer-executable instructions and / or data structures is a transmission medium. Therefore, embodiments of the present invention may comprise at least two distinctly different types of computer-readable media, namely 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. A physical storage medium includes computer hardware such as RAM, ROM, EEPROM, solid-state drives ("SSD"), flash memory, phase-change memory ("PCM"), optical disk storage devices, magnetic disk storage devices 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 dedicated computer system for implementing the functions disclosed in this 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 networks and / or data links that can be accessed by general-purpose or dedicated computer systems. “Network” is defined as one or more data links that enable the transfer of electronic data between computer systems and / or modules and / or other electronic devices. When information is transferred to or provided to a computer system via a network or another communication connection (either wired, wireless, or a combination of wired and wireless), the computer system may consider the connection to be a transmission medium. The above combinations should also be included within the scope of computer-readable media.

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

[0074] Computer executable instructions consist of instructions and data that, when executed on one or more processors, cause a particular function or group of functions in a general-purpose computer system, a dedicated computer system, or a dedicated processing device. Computer executable instructions can be, for example, binary, intermediate format instructions such as assembly language, or source code.

[0075] Those skilled in the art will understand that the present invention can be put into practice in network computing environments 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 can also be put into practice in distributed system environments where both local and remote computer systems linked through a network (by hardwired data links, wireless data links, or a combination of hardwired and wireless data links) perform tasks. Thus, in a distributed system environment, the computer system may include multiple configured computer systems. In a distributed system environment, program modules may reside in both local and remote memory storage devices.

[0076] Those skilled in the art will also understand that the present invention can be practiced in a cloud computing environment. A cloud computing environment can be distributed, but is not required. When distributed, a cloud computing environment may have components that are internationally distributed within an organization and / or held across multiple organizations. In this specification and the following claims, “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 many other benefits that can be obtained from such a model when properly deployed.

[0077] Cloud computing models can comprise a variety of characteristics, including on-demand self-service, extensive network access, resource pooling, rapid adaptability, and measured service. Cloud computing models can also be presented in the form of various service models, such as Software as a Service ("SaaS"), Platform as a Service ("PaaS"), and Infrastructure as a Service ("IaaS"). Cloud computing models can also be deployed using different deployment models, such as private clouds, community clouds, public clouds, and hybrid clouds.

[0078] Some embodiments, such as cloud computing environments, may comprise a system comprising one or more hosts, each capable of running one or more virtual machines. While in operation, a virtual machine emulates an operating system, supporting an operating system and possibly one or more other applications as well. In some embodiments, each host includes a hypervisor that emulates the virtual resources of a virtual machine using physical resources abstracted from the virtual machine's view. The hypervisor also provides adequate isolation between virtual machines. Therefore, from the perspective of any given virtual machine, the hypervisor provides the illusion that the virtual machine is interfaced with physical resources, even though the virtual machine only interfaces with the 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 will be further described by the following embodiments.

[0080] In the first embodiment, a computer system for dynamically controlling printing parameters in a three-dimensional printer having a plurality of extruders is preferably provided using a three-dimensional printer according to any one of embodiments 18 to 23, the computer system comprising one or more processors and one or more computer-readable media storing executable instructions, and the computer system is configured to, when an executable instruction is executed by one or more processors, perform at least the following: receive an index for printing a target object by the three-dimensional printer; access a material attribute dataset, the material attribute dataset describing different material properties of a plurality of thermosetting materials or mixtures thereof; select one or more thermosetting materials from a plurality of thermosetting materials for each of the plurality of extruders to form an extruded body for each of the plurality of extruders based on the material attribute dataset; determine the extrusion configuration of the selected one or more thermosetting materials; and generate 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] Embodiment 2 relates to a computer system according to Embodiment 1, wherein the plurality of extruders include 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 of each of the plurality of extruders includes 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, preferably the first set of material properties is different from the second set of material properties.

[0082] Embodiment 3 relates to the computer system described in Embodiment 1 or 2, wherein the target object has a plurality of parts having different material properties, and for each of the plurality of parts, the computer system is further configured to select one or more thermosetting materials from a plurality of thermosetting materials to form an extruded body, select one of a plurality of extruders, and determine a specific extrusion configuration for the selected extruder and the extruded body.

[0083] Embodiment 4 relates to the computer system described in Embodiment 3, wherein for each of the plurality of parts, the computer system is further configured to determine a volumetric mixing ratio of one or more selected thermosetting materials, and a command is configured to cause one or more selected thermosetting materials to be supplied to a selected extruder at the determined volumetric mixing ratio.

[0084] Embodiment 5 relates to any one of the computer systems described in Embodiments 1 to 4, wherein the different material properties include at least the fluidity or gelity of a plurality of thermosetting materials in different proportions prior to the co-reaction, or a mixture thereof.

[0085] Embodiment 6 relates to any one of the computer systems described in Embodiments 1 to 5, wherein the different material properties include, at least, hardness, flexibility, tensile strength, color, temperature resistance, sound dampening, expansion, flame retardancy, pulverability, expandability, conductivity of multiple thermosetting materials, or mixtures thereof, in different ratios after co-reaction.

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

[0087] Embodiment 8 relates to any one of the computer systems described in Embodiments 1 to 7, wherein multiple extruders are used sequentially to produce a single tool path.

[0088] Embodiment 9 relates to any one of the computer systems described in Embodiments 1 to 8, wherein each of the multiple extruders is coupled to a separate set of material sources.

[0089] Embodiment 10 further relates to any one of the computer systems described in Embodiments 1 to 9, and includes calculating an offset between a first extruder selected from a plurality of extruders and a second extruder selected from a plurality of extruders; receiving a command to switch extrusion from the first extruder to the second extruder; and using the offset to position the second extruder relative to the first extruder before extruding material from the second extruder.

[0090] Embodiment 11 relates to any one of the computer systems described in Embodiments 1 to 10 and further includes receiving a command to switch the extrusion of a first material from a first extruder to a second material, retrieving a purge entry from a material database, wherein the purge entry indicates the amount and configuration of extrusion required to purge the first material from the first extruder, positioning the first extruder in a purge area, and purging the amount of extrusion required to purge the first material from the first extruder.

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

[0092] Embodiment 14 relates to any one of the computer systems described in Embodiments 1 to 13, wherein the computer system comprises two to five extruders, preferably two to four extruders, more preferably three to four extruders.

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

[0094] Embodiment 16 relates to the computer system described in Embodiment 3, wherein the selection of one or more thermosetting materials and one of a plurality of extruders is based on the different material properties of each part of the target object, and in particular takes into account the different material properties of one or more thermosetting materials.

[0095] Embodiment 17 relates to a computer system according to any one of Embodiments 1 to 16, wherein each extruder utilizes different thermosetting materials or mixtures of thermosetting materials in order to dynamically control the different material properties of different parts of a target object.

[0096] In the 18th embodiment, a three-dimensional printer is provided, preferably in a computer system according to any one of embodiments 1 to 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 storing executable instructions, wherein when the executable instructions are executed by one or more processors, the three-dimensional printer is configured to, preferably using the method according to embodiment 24 or 25, at least to receive a command for printing a target object, select one or more thermosetting materials from a plurality of thermosetting materials for each of the plurality of extruders 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] Embodiment 19 relates to the three-dimensional printer described in Embodiment 18, wherein the command for printing a target object indicates one or more thermosetting materials selected for each of the multiple extruders.

[0098] Embodiment 20 relates to the three-dimensional printer described in Embodiment 18 or 19, wherein the command for printing a target object further indicates the volumetric mixing ratio of one or more selected thermosetting materials for each of the multiple extruders.

[0099] Embodiment 21 relates to a three-dimensional printer according to any one of embodiments 18 to 20, and further comprises a plurality of material sources configured to supply one or more thermosetting materials to each of a plurality of extruders.

[0100] Embodiment 22 relates to the three-dimensional printer described in any one of Embodiments 18 to 21, further comprising a movable arm, wherein a plurality of extruders are coupled to the movable arm, and the plurality of extruders are configured to extrude in succession.

[0101] Embodiment 23 relates to a three-dimensional printer according to any one of embodiments 18 to 22, wherein multiple extruders are used simultaneously to produce a single tool path.

[0102] In the 24th aspect, a computer implementation method is provided for dynamically controlling a thermosetting three-dimensional printer to produce desired material attributes, the computer implementation method is performed on one or more processors, preferably using a computer system according to any one of aspects 1 to 17, the method comprising: receiving an index for printing a target object using a thermosetting three-dimensional printer, preferably by a three-dimensional printer according to any one of aspects 18 to 23; accessing a material attribute dataset, the material attribute dataset describing different material properties of a plurality of thermosetting materials being printed; selecting one or more thermosetting materials from a plurality of thermosetting materials for each of a plurality of extruders to form an extruded body, for each of a plurality of extruders, based on the material attribute dataset; determining an extrusion configuration of 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] Embodiment 25 relates to the computer implementation method of Embodiment 24, wherein the plurality of extruders include 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 a first set of material properties and configuring the second extruder to extrude a material having a second set of material properties.

[0104] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. It should be considered that the embodiments described are, in all respects, merely illustrative and not limiting. Accordingly, the scope of the present invention is indicated not by the foregoing description but by the appended claims. All modifications that fall within the equivalent meaning and scope of the claims shall be incorporated within that scope.

Claims

1. A computer system for dynamically controlling printing parameters in a three-dimensional printer having multiple extruders, One or more processors, A computer system comprising one or more computer-readable media storing executable instructions, wherein when the executable instructions are executed by the one or more processors, the computer system is configured to at least The three-dimensional printer receives an indicator for printing a target object, Accessing a material attribute dataset, wherein the material attribute dataset describes different material properties of multiple thermosetting materials or mixtures thereof. Based on the material attribute dataset, for each of the plurality of extruders, To form an extruded product, one or more thermosetting materials are selected from the plurality of thermosetting materials for each of the plurality of extruders, Determining the extrusion configuration of one or more selected thermosetting materials, A computer system configured to generate and execute commands to cause the multiple extruders of the three-dimensional printer to implement the extrusion configuration of the multiple extruders while the target object is being printed.

2. The aforementioned multiple extruders 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 is The first extruder is configured to extrude a material having a first set of material properties, The computer system according to claim 1, comprising configuring the second extruder to extrude a material having a second set of material properties.

3. The target object has a plurality of parts having different material properties, and for each of the plurality of parts, the computer system To form an extruded product, one or more thermosetting materials are selected from a group of thermosetting materials, Selecting one of the aforementioned multiple extruders, The computer system according to claim 2, further configured to determine a specific extrusion configuration of the selected extruder and the extruded product.

4. The target object has a plurality of parts having different material properties, and for each of the plurality of parts, the computer system To form an extruded product, one or more thermosetting materials are selected from a group of thermosetting materials, Selecting one of the aforementioned multiple extruders, The computer system according to claim 1, further configured to determine a specific extrusion configuration of the selected extruder and the extruded product.

5. The computer system according to claim 4, wherein for each of the plurality of parts, the computer system is further configured to determine the volumetric mixing ratio of the selected one or more thermosetting materials, and the command is configured to cause the selected one or more thermosetting materials to be supplied to the selected extruder at the determined volumetric mixing ratio.

6. The computer system according to claim 1, wherein the different material properties include, at least, the fluidity or gelity of the plurality of thermosetting materials in different proportions prior to the co-reaction, or a mixture thereof.

7. The computer system according to claim 6, wherein the different material properties include, at least, hardness, flexibility, tensile strength, color, temperature resistance, sound absorption, expansion, flame retardancy, pulverability, expandability, conductivity of the plurality of thermosetting materials, or a mixture thereof, in different ratios after co-reaction.

8. The computer system according to claim 1, wherein for each of the plurality of extruders, the extrusion configuration includes at least one of extrusion speed, extrusion timing, or extrusion path.

9. The computer system according to claim 1, wherein the plurality of extruders are used in sequence to produce a single tool path.

10. The computer system according to claim 1, wherein each of the plurality of extruders is coupled to a separate set of material sources.

11. Calculating the 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, The computer system according to claim 1, further comprising using the offset to position the second extruder relative to the first extruder before extruding material from the second extruder.

12. Receiving a command to switch the extrusion of the first material from the first extruder to the second material, Retrieving a purge entry from a material database, wherein the purge entry indicates the amount and configuration of extrusion required to purge the first material from the first extruder. Positioning the first extruder in the purging area, The computer system according to claim 2, further comprising purging an amount of extrusion required to purge the first material from the first extruder.

13. A computer implementation method for dynamically controlling a thermosetting three-dimensional printer to produce desired material attributes, wherein the computer implementation method is executed on one or more processors, and the method The thermosetting three-dimensional printer receives an index for printing a target object, Accessing a material attribute dataset, wherein the material attribute dataset describes different material properties of multiple thermosetting materials being printed. Based on the aforementioned material attribute dataset, for each of the multiple extruders, To form an extruded product, one or more thermosetting materials are selected from the plurality of thermosetting materials for each of the plurality of extruders, Determining the extrusion configuration of one or more of the thermosetting materials, A computer implementation method comprising generating commands to cause the plurality of extruders of the thermosetting three-dimensional printer to implement the extrusion configuration while the target object is being printed.

14. The aforementioned multiple extruders A first extruder having a first set of extrusion properties, A second extruder having a second set of extrusion properties, Determining the extrusion configuration is The first extruder is configured to extrude a material having a first set of material properties, The computer mounting method according to claim 13, comprising configuring the second extruder to extrude a material having a second set of material properties.

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