Near Net Shape Additive Manufacturing

Abstract

A low-cost or space-saving apparatus and method for fabricating components via additive manufacturing techniques or processes is provided. The additive manufacturing apparatus includes a first vertically extending support leg, a second vertically extending support leg, a gantry supported by the first and second support legs, a worktable movably supported below the gantry, a print head supported by the gantry, and a trim head supported by the gantry together with the print head.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This patent application claims the benefit of priority to U.S. Patent Application No. 16 / 692,825, filed November 22, 2019, which is incorporated by reference in its entirety.

[0002] (Technical field) Aspects of the present disclosure relate to apparatus and methods for fabricating components, in some cases, to apparatus and methods for fabricating components (e.g., automotive parts, medical devices, machine parts, consumer products, etc.) via additive manufacturing techniques or processes, such as, for example, 3D printing manufacturing techniques or processes. [Background technology]

[0003] Additive manufacturing techniques and processes generally involve the build-up of one or more materials to create a net or near net shape (NNS) object, as opposed to subtractive manufacturing methods. Although "additive manufacturing" is an industry standard term (ASTM F2792), additive manufacturing includes a variety of manufacturing and prototyping techniques known by a variety of names, including, for example, freeform fabrication, 3D printing, rapid prototyping / tooling, and others. Additive manufacturing techniques can be used to manufacture simple or complex components from a wide variety of materials. For example, freestanding objects can be created from computer-aided design (CAD) models.

[0004] A particular type of additive manufacturing is commonly known as 3D printing. One such process, commonly referred to as Fused Deposition Modeling (FDM) or Fused Layer Modeling (FLM), involves melting a thin layer of thermoplastic material and applying this material in layers to produce the final part. This is generally achieved by passing a continuous thin filament of thermoplastic material through a heated nozzle, melting the material and applying it to the structure to be printed. The heated material is applied in thin layers to an existing structure, where it can melt and fuse with the existing material to produce a solid finished part.

[0005] The filaments used in the aforementioned process can be produced, for example, using a plastic extruder, which can include a steel extruder screw configured to rotate inside a heated steel barrel. The thermoplastic material can be introduced into one end of the rotating screw in the form of small pellets. The friction of the rotating screw combined with the heat of the barrel can soften the plastic, which is then extruded under pressure through a small round opening in a die attached to the end of the extruder barrel. This can then be used to extrude a string of material that is cooled and wound for use in a 3D printer.

[0006] Melting thin filaments of material to 3D print an article can be a slow process that may be suitable for producing relatively small articles or a limited number of articles. Thus, the molten filament approach to 3D printing may be too slow for producing large articles. However, the basic process of 3D printing using molten thermoplastic material can offer advantages for the production of larger parts or more articles.

[0007] In some examples, the process of 3D printing a part can include a two-step process. For example, the process can utilize large print beads to achieve the exact final size and shape. This two-step process, commonly referred to as near net shape, begins by printing the part slightly larger than required, and then the part can be machined (e.g., milled or routed) to the final size and shape. The additional time required to trim the part to the final size can be compensated for by the faster printing process.

[0008] Print heads of additive manufacturing machines used to print relatively large beads of thermoplastic material have typically included a vertically mounted plastic extruder connected to a print nozzle for depositing a bead of material onto the surface and / or part being printed. For example, the flowable material, such as a molten thermoplastic material, can be infused with a reinforcing material (e.g., bundles of fibers) that increase the strength of the material. The flowable material is generally flexible at high temperatures, but can be deposited onto a substrate (e.g., a mold) and then pressed down or otherwise flattened and / or leveled to a certain thickness. Conventional print heads can include a vibrating plate surrounding the nozzle, configured to vibrate vertically to flatten the bead of material against the surface or part onto which it is deposited, which can include a previously deposited bead of material. The deposition process is repeated such that each successive layer of flowable material is deposited onto an existing layer, allowing the desired structure of the component or part to be built and manufactured. To achieve proper bonding between the printed layers, it may be necessary to ensure that the temperature of the layer being printed is within a certain range as the layer is deposited thereon. For example, a previously deposited layer may need to be cooled to an appropriate degree so that it is solid enough to support a new layer, but this pre-deposited layer must retain enough heat to soften and fuse the new layer, thus producing a solid part at the end of the manufacturing process.

[0009] In near-net-shape additive manufacturing or 3D printing, a desired part can be printed in a series of layers. These layers can be slightly larger than the desired size of the finished part. After these layers cool and solidify, the part can be trimmed to the desired final size and shape. This approach can offer the advantage of printing relatively quickly with relatively large print beads and then machining or trimming the printed part to its final size and shape. This can be significantly faster than printing with print beads that are fine enough to achieve the final size and shape using the printing process alone.

[0010] Near net shape additive manufacturing can include two processes: a printing process and a trimming process. Traditionally, these two processes can be performed on separate machines in different locations. However, it may be desirable to perform these two separate processes on a single machine. To perform these processes on a single machine, the machine can include two gantries, one for printing and one for trimming. Providing separate gantries can be suitable for relatively large machines, such as machines having a footprint or print area of ​​at least 10 feet by 20 feet, but including separate printing and trimming devices can result in significant costs. Furthermore, including separate gantries can increase the size of the machine and may be less suitable for smaller machines, such as machines having a footprint or print area of ​​about 10 feet by 10 feet. Summary of the Invention

[0011] Aspects of the present disclosure relate, inter alia, to methods and apparatus for producing components via additive manufacturing or 3D printing techniques. Each of the aspects disclosed herein may include one or more of the features described in connection with any of the other disclosed aspects. An exemplary aspect of the present disclosure is a machine configured to perform both printing and trimming operations, which can be manufactured at low cost. The exemplary machine can have a smaller size than other dual gantry machines, and therefore require less space.

[0012] In one aspect, an additive manufacturing apparatus can include a first vertically extending support leg, a second vertically extending support leg, and a gantry supported on the first and second support legs. The additive manufacturing apparatus can also include a worktable movably supported below the gantry, a print head supported on the gantry, and a trim head supported on the gantry along with the print head.

[0013] In another aspect, the additive manufacturing apparatus can include a fixed gantry, a support for a print head on the gantry, and a support for a trim head on the gantry along with the print head. The additive manufacturing apparatus can include a vertical worktable including a side configured to receive a bead of thermoplastic material extruded from the print head, and a support member extending below a side of the vertical worktable to support a part.

[0014] In another aspect, an additive manufacturing method can include depositing a first layer of thermoplastic material on a surface using a print head supported on a gantry and moving the surface with the deposited thermoplastic material away from the print head. The additive manufacturing method can also include depositing one or more additional layers of thermoplastic material on the first layer of thermoplastic material and supporting at least a portion of the first layer of thermoplastic material or the one or more additional layers on a support member.

[0015] In yet another aspect, the machine can include a gantry (extending along the Y-axis) mounted above a horizontally moving print surface or worktable. Once installed or assembled, the gantry can be fixed in place (e.g., the gantry does not include a motor, such as a servo motor, that moves the gantry relative to the worktable). For example, the gantry can be fixed, but the worktable can be movable back and forth (along the x-axis) relative to the gantry. Two separate heads that are vertically (z-axis) movable can be mounted on the gantry. The first of these vertically movable heads can be a print head for depositing material to fabricate or print a part, and the other vertically movable head can be a trim head for removing material from the part fabricated by the print head. The gantry can be sized to include opposing sides of the worktable and portions that extend beyond each side of the worktable. Thus, the gantry can provide full coverage of the worktable.

[0016] In an exemplary arrangement, the print head and trim head can be connected to each other to move back and forth along the gantry as a unit. Alternatively, the trim head can be movable independently of the print head so that the trim head can park or retract at a position away from the part printed on the table during printing. In such a configuration, once the part cools and solidifies to a nearly solid state, the print head can be moved up and parked or retracted. The park position for the print head and trim head can be away from the table (e.g., at the side of the table). Thus, during printing of the part, the trim head can be moved completely away from the table (to the side of the table) to park during printing of the part, and during trimming, the print head can be parked instead. In a configuration where the print head and trim head are connected and move as a unit, the park position can instead be an elevated position relative to the z-axis such that the parked head is positioned above the active head. Once the part cools, the trim head can be lowered and pulled to the printed part to trim the part. In this manner, the part can be trimmed using the trim head while the print head is parked. In such a configuration, the print head and trim head can operate independently while moving as a unit relative to the gantry. Whether connected or provided as separate components, the print head and trim head can be supported on a single gantry, which allows for the production of parts as large as the table, with heights limited only by the vertical stroke of the print head, due at least in part to the movable worktable.

[0017] In one aspect, it may be desirable to produce relatively small parts with a height greater than the vertical (z-direction) stroke of the print head. In such cases, the machine can be reconfigured to print vertically rather than horizontally. For example, the machine can include at least one print nozzle that, when installed in the machine, allows material to flow (and be deposited) horizontally rather than vertically. A second vertically extending table, having a height approximately equal to the vertical stroke of the print head, can be mounted vertically behind the moving horizontal table to facilitate horizontal deposition of material (e.g., on a vertically extending surface) for vertical printing.

[0018] The vertical table can be movable relative to the print head. Parts can be printed vertically on the vertical table with the table positioned adjacent to the print head. After each layer is printed, the combined horizontal and vertical tables can be moved together away from the print head the distance required to print the next layer or bead.

[0019] In at least some configurations, the horizontally extending print nozzle may not deposit material on the surface of the horizontal table when it deposits material on the vertical worktable instead. Thus, during the manufacturing process, the manufactured part may be suspended on the vertical worktable above the horizontal table. In one aspect, the distance between the horizontal table and the suspended part may initially be equal to a distance that ensures that the print head has sufficient clearance above the horizontal worktable during manufacturing. As the part grows, it may benefit from a support to prevent it from slipping off the vertical table. To provide such support, one or more support members, such as conveyors or support rails, may extend through one or more openings in the bottom of the vertical table. These conveyors may extend from the horizontal worktable to a location of the underside of the part. One or more rollers may be provided below the conveyor and may rest on the horizontal table to support the weight of the part being manufactured. The rear of the conveyor may be mounted in a fixed position at the rear of the machine such that the front of the conveyor is located slightly behind the location of the nozzle that deposits and prints each layer of material.

[0020] For parts that do not have a flat bottom, other forms of removable supports can be used to secure and support the part. The part can be stationary relative to the horizontal worktable (e.g., the horizontal worktable and printed part can move together as a unit), or the horizontal worktable can include one or more supports, such as blocks (which can include any suitable material, such as metal, wood, etc.), mechanical lifts, hydraulic jacks, and the like.

[0021] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary aspects of the present disclosure and, together with the description, serve to explain the principles of the disclosure. [Brief description of the drawings]

[0022] [Figure 1] FIG. 1 illustrates a perspective view of an exemplary CNC machine having a moving worktable operable to form an article via additive manufacturing, according to one embodiment of the present disclosure. [Diagram 2] FIG. 2 is a perspective view of an exemplary carrier and extruder assembly of the CNC machine shown in FIG. [Diagram 3] FIG. 2 is an enlarged perspective view of an example carrier and applicator assembly of the example CNC machine shown in FIG. [Figure 4] FIG. 2 is a close-up perspective view of an exemplary carrier and applicator head for vertical printing using the CNC machine shown in FIG. [Diagram 5] FIG. 5 is an enlarged cross-sectional view of the exemplary applicator head shown in FIGS. 3 and 4. [Figure 6] FIG. 2 is a side view of the example CNC machine and work table shown in FIG. [Figure 7] FIG. 7 is an enlarged side view of the indicated portion of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The present disclosure relates, inter alia, to methods and apparatus for manufacturing multiple components via additive manufacturing or 3D printing technology. In particular, the methods and apparatus described herein provide machine designs that can perform both print and trim operations for near net shape additive manufacturing while at the same time being less costly. Additionally, the methods and apparatus can provide machines that can require less space than dual gantry designs.

[0024] With reference to FIG. 1, an additive manufacturing apparatus or CNC machine 1 may include a horizontal worktable 27 including a horizontal surface disposed in an xy (horizontal) plane. The horizontal worktable 27 including the horizontal surface may be movable along a set of guide rails 21, 22, 23. Each of the guide rails 21, 22, 23 may extend along an x-axis on the bed 20. A gantry 26 may extend horizontally above the worktable 27. In the exemplary configuration shown in FIG. 1, the gantry 26 may extend along a y-axis that is orthogonal or nearly orthogonal to the x-axis. The gantry 26 may extend horizontally across at least the entire width of the worktable 27. The gantry 26 may be supported on a pair of vertically extending support legs 85 and 86 that are attached to the bed 20. The gantry may be fixed in place (e.g., the gantry does not include mechanisms or motors, such as servo motors, for moving the gantry vertically, horizontally, or both). If desired, a smoke extraction system may be provided within one or both of the support legs 85 and 86 to remove smoke and / or fumes generated during operation of the CNC machine 1.

[0025] A pair of carriages, such as print carriage 24 and trim carriage 48, may be supported on gantry 26. In one aspect, carriages 24 and 48 may be supported together on a single support member 30 that is mounted to and displaceable along one or more guide rails 31, 32, and 33. Guide rails 31, 32, and 33 may be provided on gantry 26 to extend along the Y axis. Carriages 24, 48 may be displaceable as a unit along the y axis on one or more guide rails 31, 32, and 33 by servo motor 79. As shown in FIG. 1, rails 31, 32, and 33 may be mounted on gantry 26 and operably connected to support member 30. Guide rails 31, 32, and 33 may extend greater than the width of worktables 27 and 37 in at least some configurations. In an alternative configuration, the carriages 24 and 48 may be provided with separate support members (e.g., multiple support members 30) and separate servo motors so as to be displaceable along one or more guide rails 31, 32, 33 (and the Y axis) independently of one another.

[0026] The trim carrier 50 for the trim head 90 may be mounted on a set of spaced apart, vertically extending guide rails 28, 29. The guide rails 28, 29 may be supported on the trim carriage 48 for displacing the trim carrier 50 and trim head 90 relative to the trim carriage 48 along the vertical or z-axis. Similarly, the print carrier 25 for the print head (or applicator head) 43 may be mounted on a set of spaced apart, vertically extending guide rails 34, 35 supported on the print carriage 24 for displacing the print carrier 25 relative to the print carriage 24 along the z-axis. The print carrier 25 and trim carrier 50 may be slidably displaced in the z-axis by two or more servo motors mounted on the print carriage 24 and trim carriage 48, respectively, and operably connected to the print carrier 25 and trim carrier 50, respectively. The trim carrier 50 can be configured to be moved to an upper parked position above the upper edge of the vertical worktable 37 to avoid interference with the print carrier 25 or with the part being manufactured. For example, the trim carrier 50 can be parked while the print carrier 25 is active and moving relative to the worktable 27. Similarly, the print carrier 25 can be moved upward and parked together while the trim carrier 50 is operating. In a configuration in which the print carrier 25 and trim carrier 50 are separate and independently movable about the Y axis, one of the carriers 25, 50 is positioned or parked to the side of the table along the Y axis while the other of the carriers 25, 50 operates above the horizontal worktable 27, allowing the operating carrier to move laterally relative to the worktable 27 without interfering with the other carrier.

[0027] A vertical worktable 37 can be removably attached to the top or surface of the horizontal worktable 27 for printing parts vertically. A conveyor or support member 36, such as a slide or support rail, can be removably attached to the end of the bed 20. In one embodiment, the support member 36 can be provided as a plurality of rails 36 extending along the x-axis and configured to roll and / or slide relative to a wear plate 87 supported on the top of the horizontal worktable 27. The wear plate 87 can extend below the vertical worktable 37 as shown in FIG. 1. The vertical worktable 37 can be configured to move backwards from the perspective of FIG. 1 in a direction away from the gantry 26 (along the x-axis) while the support member 36 remains in a substantially constant position relative to the gantry 26 below the vertical worktable 37 to support the vertically printed parts. As described below, parts can slide along the surface of one or more support members 36 during production in this manner.

[0028] The extruder 61 (FIG. 1) may be mounted for linear movement relative to the carrier 25 by a set of rails 34 and 35 and bearings (not shown) on the rails 34 and 35. Referring to FIG. 2, the extruder 61 may be driven by a servo motor 38 through a gear box 39 mounted in a transition housing 37. The extruder 61 may receive thermoplastic pellets via a feed housing 40. An extruder screw of the extruder 61 may transport the thermoplastic material through a barrel 42 where the pellets are melted by friction of the rotating screw and / or heat generated by a heater 41. The melted thermoplastic material may be fed by the extruder 61 to a positive displacement gear pump 62 (FIGS. 3 and 4).

[0029] As best shown in FIG. 3, a positive displacement gear pump (or melt pump) 62 may be fixedly mounted to the bottom of the carrier 25. The gear pump 62 may be driven by a servo motor 63 via a gear box 64. The gear pump 62 may receive molten plastic material from an extruder 61 as described above to meter a precise amount of thermoplastic material at a determined flow rate to the nozzle 51 for printing the part. The use of both the extruder 61 and melt pump 62 together may provide the ability to utilize extruder screw configurations that may cause uneven flow in configurations where only an extruder is provided. In one aspect, the melt pump acts to even out the material flow and allows for greater freedom in the design of the extruder screw.

[0030] The print head or applicator head 43 may be mounted below the gear pump 62. The applicator head 43 may include a bead shaping roller 59 rotatably mounted on a carrier bracket 47 to provide a means for flattening and leveling an oversized bead of fluid material (e.g., molten thermoplastic material) extruded by the nozzle 51. The carrier bracket 47 may be adapted to be rotationally displaced by a servo motor 60. For example, the servo motor 60 may be operatively connected to the carrier bracket 47 by a pulley or sprocket 56 and a belt or chain 65. The applicator head 43 and nozzle 51 may be used to print horizontally, for example on a horizontally extending surface such as a horizontal worktable 27, as shown in FIG. 1. When horizontal printing is performed, the vertical worktable 37, supporting slide rails 36, and wear plate 87 may be removed from the CNC machine 1. The applicator head 43 may include a safety bumper 82 provided around the periphery of the applicator head 43 to pause or stop operation of the CNC machine 1 if an obstacle is encountered.

[0031] Referring to FIG. 4, the applicator head 43 can be fixed below the gear pump 62 in a position that is angled or rotated 90° relative to the print carrier 25 compared to the position of the applicator head 43 shown in FIG. 3. Thus, the configuration of FIG. 3 can be adopted for printing on a horizontal surface (e.g., horizontal worktable 27). This configuration is sometimes referred to as a horizontal printing configuration. The configuration shown in FIG. 4 can be adopted for printing on a vertical surface (e.g., vertical worktable 37) and is referred to herein as a vertical printing configuration. In each of the horizontal and vertical printing configurations shown in FIG. 3 and FIG. 4, respectively, the applicator head 43 itself can have the same shape and components. The 90° change in the position of the applicator head 43 between these configurations can be achieved by installing a 90° angle transition joint 83 between the gear pump 62 and the nozzle 51 (see FIG. 3), as shown in FIG. 4. Additional support for the applicator head 43 can be provided by one or more 90° mounting plates 84 for connection to the applicator head 43. In an exemplary vertical printing configuration shown in FIG. 4, a pair of 90° mounting plates 84 can be provided on opposite sides of a 90° angled transition joint 83. When the applicator head 43 and gear pump 62 are connected to each other by a 90° angled transition joint 83, the applicator head 43 can be configured to print vertically on a vertical worktable 37 by extending material through a horizontally extending nozzle 51, as shown in FIG. 1. Also, in the vertical printing configuration, the gear pump 62 can be driven by the same servo motor 63 and gear box 64 as the horizontal printing configuration shown in FIG.

[0032] When in a horizontal print configuration, CNC machine 1 can print parts as tall as its height (z-axis) limit corresponds to the maximum print height of CNC machine 1. When in a vertical print configuration, the CNC machine can print parts as long as its length (x-axis) limit corresponds to the available horizontal worktable space.

[0033] Referring to FIG. 5, the applicator head 43 can include a housing 46 having a rotary union attached thereto. The sprocket 56 can be machined into an inner hub 76 of the rotary union. The inner hub 76 can have an opening with a diameter sized to receive the heated print nozzle 51. The inner hub 76 can rotate on a set of bearings 49 mounted in an outer housing 75 of the rotary union. The compression roller assembly can be mounted on the inner hub 76 of the rotary union such that the compression roller 59 rotates about the print nozzle 51. The rotary union can also include barb fittings 67 and 68 in fluid communication with a coolant passage 70. In one aspect, the coolant passage 70 can surround the inside of the inner hub 76 and the outer housing 75 of the rotary union. The coolant passage 70 can continue through a quick disconnect fitting 72 to an axle 73 of the compression roller 59. Applicator head 43 can be used in both horizontal and vertical printing configurations (by fitting a 90° angled transition joint 83 and optionally one or more 90° mounting plates 84).

[0034] As shown in FIGS. 3-5, an oversized molten bead of flowable material (e.g., molten thermoplastic) can be provided under pressure to the applicator head 43 from a source (e.g., gear pump 62) or another source disposed on the carrier 25. The material can be provided to a nozzle 51 in communication with the applicator head 43, which can be fixedly connected to the carrier 25. In use, the flowable material 53 (e.g., thermoplastic material) can be heated sufficiently to form a large molten bead, which is then extruded through the applicator nozzle 51 to form a substantially uniform, smooth column of deposited material on the worktable 27, 37 in a series of layers. Such beads of molten material can be flattened, leveled, and / or fused to adjacent layers, substantially free of trapped air, by bead forming compression rollers 59 in layers forming the 3D printed product.

[0035] FIG. 6 is a side view of the CNC machine 1 with the gantry support legs 85 omitted for clarity. The removable vertical worktable 37 is attached and used in combination with the vertical printing configuration of the applicator head 43 to allow the CNC machine 1 to produce relatively long parts without increasing the height of the machine. The vertical worktable 37 can be attached directly to the top end of the movable horizontal worktable 27. One or more removable support members 36, such as rails, can be fixed below the vertical worktable 37 to support vertically printed parts. The support members 36 can slide or roll (e.g., by rollers) against a wear plate 87 fixed (e.g., by bolts) to the horizontal worktable 27. For example, once a layer of thermoplastic material has been deposited in one or more rows on the vertical worktable 37, the horizontal and vertical worktables 27, 37 can move as a unit away from the applicator head 43. During this movement, the horizontal worktable 27 can slide along the rollers of the support members 36. As the rollers rotate due to the movement of the worktable 27, the rollers and support member 36 can remain in a substantially constant position. Thus, as layers of the part are deposited, the support member 36 can form a shelf surface against which the applicator head 43 can print and provide support to the part.

[0036] The removable support member 36 may be advanced through an opening in the bottom of the vertical worktable 37 by movement of the vertical worktable 37 while the vertical worktable 37 moves away from the applicator head 43. The part may be supported with respect to gravity by the support member 36. Additionally, the part may slide across the top surface of the support member 36 while remaining fixed to the vertical worktable 37. As mentioned above, the vertical worktable 37, support member 36, and wear plate 87 may be removable, after which the CNC machine 1 may place the applicator head 43 in a horizontal printing configuration to print across the entire top surface of the horizontal worktable 27.

[0037] FIG. 7 is an enlarged view of the cross section of FIG. 6 within the dashed box. Thermoplastic material 53 can be extruded horizontally from applicator head 43 through nozzle 51 (behind compression roller 59 from the perspective of FIG. 7) onto the surface of vertical work table 37. In one configuration, this vertical surface can be provided on a pellet or bead board 80 secured to a base board 81. Compression roller 59 can be configured to compress and flatten bead 53 against pellet board 80. Both pellet board 80 and base board 81 can be removably secured to vertical work table 37. After a first layer of thermoplastic material is deposited on the side of pellet board 80, and before nozzle 51 begins depositing the next layer, vertical work table 37 can be pulled or moved away from applicator head 43, as described above. In one embodiment, the distance of this movement of vertical work table 37 can be approximately equal to the thickness of one layer of bead of thermoplastic material 53. One or more additional layers can be deposited on top of the first layer. After deposition of each layer, the above-described movement can be repeated. In one aspect, this motion may be performed by a servo motor and gear box controlled using feedback from one or more encoders. When the vertical worktable 37 is pulled away from the applicator head by the distance of one layer of material 53, the support members 36 remain in place, allowing the part to slide along the support surface formed on the top of each support member 36.

[0038] This process can be repeated until a part is completed, which can have a length equal to the length of the horizontal worktable 27. As the vertical worktable 37 moves away from the applicator head 43 layer by layer, the length of the part increases and the part can slide layer by layer along the surface of the support member 36. Thus, the bottom surface of the growing part can be slidably supported on the support member or rail 36. Any of the layers, including the first layer or one or more additional layers, can be supported on the support member 36. In an exemplary configuration, when the part reaches a sufficient length due to the deposition of multiple layers, the part may extend downward a sufficient distance to reach the support member 36. Thus, the support member 36 can prevent undesired separation of the part from the vertical worktable 37 and / or the pellet board 80.

[0039] From the foregoing detailed description, it will be apparent that there are numerous changes, adaptations and modifications of the present invention that are within the purview of those skilled in the art to which the invention pertains, however, all such variations that do not depart from the spirit of the present invention are intended to be considered within its scope as defined by the appended claims. Other embodiments of the invention are described below. [Embodiment 1] 1. An additive manufacturing apparatus comprising: a fixed gantry; a support for a printhead on the gantry; a trim head support that is on the gantry with the print head; a vertical worktable including a side configured to receive a bead of thermoplastic material extruded from the printhead; a support member extending below the side of the vertical worktable to support a part; An additive manufacturing apparatus comprising: [Embodiment 2] An additive manufacturing apparatus as described in embodiment 1, wherein the vertical worktable is movable relative to the support member. [Embodiment 3] 3. An additive manufacturing apparatus as described in embodiment 2, further comprising a horizontal worktable connected to the vertical worktable, wherein the horizontal worktable and the vertical worktable are movable together relative to the support member during operation of the print head or the trim head. [Embodiment 4] 2. An additive manufacturing apparatus as described in claim 1, wherein the support member extends through an opening in the vertical worktable. [Embodiment 5] 2. An additive manufacturing apparatus as described in embodiment 1, wherein the print head includes an angled support member extending from a gear pump to the print head. [Embodiment 6] 6. An additive manufacturing apparatus as described in claim 5, wherein the angled support forms an angle of approximately 90° between a proximal end connected to the gear pump and a distal end connected to the applicator head. [Explanation of symbols]

[0040] 20 Beds 21, 22, 23 Guide rail 26 Gantry 27 Horizontal Work Table

Claims

1. 1. An additive manufacturing apparatus comprising: a first support leg extending vertically; a second support leg extending vertically; a gantry supported by the first support leg and the second support leg; a work table movably supported below the gantry; a print head supported by the gantry; a trim head supported on the gantry along with the print head; Equipped with An additive manufacturing apparatus, wherein the trim head is supported on a trim carrier slidably connected to the gantry.

2. The additive manufacturing device of claim 1 , wherein the worktable includes a horizontally movable surface.

3. The additive manufacturing apparatus of claim 1 or 2, wherein the print head is supported on a print carrier slidably connected to the gantry.

4. The additive manufacturing apparatus of claim 1 , wherein the trim head is supported on a print carrier, the print carrier and the trim carrier being secured to one another by a support member.

5. An additive manufacturing apparatus according to any one of claims 1 to 4, wherein the gantry extends across at least the entire width of the worktable.

6. 2. The additive manufacturing apparatus of claim 1 , wherein the print head is supported on a print carrier slidably fixed on rails of the gantry that extend beyond a width of the worktable.

7. 2. The additive manufacturing apparatus of claim 1 , wherein the worktable includes a vertically extending surface, the vertically extending surface being movable in a direction away from the print head during operation of the print head or the trim head.

8. 1. An additive manufacturing method comprising: depositing a first layer of thermoplastic material onto a surface using a printhead supported on a gantry; moving the surface having deposited thermoplastic material away from the print head; depositing one or more additional layers of thermoplastic material onto the first layer of thermoplastic material; supporting at least a portion of the first layer or the one or more additional layers of thermoplastic material on a support member; trimming at least one of the first layer or the one or more additional layers of thermoplastic material with a trim head supported on the gantry with the printhead; A method comprising:

9. The additive manufacturing method of claim 8 , wherein the surface is a vertically extending surface.

10. 10. The additive manufacturing method of claim 8 or 9, further comprising positioning a trim head supported on the gantry together with the print head above the print head during deposition of the one or more additional layers of thermoplastic material.

11. The additive manufacturing method of claim 10 , further comprising moving the print head and the trim head together as a unit.

12. 10. The additive manufacturing method of claim 8 or 9, further comprising moving the surface, the first layer of thermoplastic material, and the one or more additional layers of thermoplastic material relative to the support member.

13. The additive manufacturing apparatus of any one of claims 1 to 7, wherein the print head comprises a compression roller configured to compress material deposited by the print head.

14. An additive manufacturing apparatus as described in any one of claims 1 to 7 and 13, further comprising a smoke extraction system provided within one or both of the first support leg and the second support leg and configured to remove smoke generated during operation.

15. An additive manufacturing method as described in claim 8 or 9, further comprising a step of supporting the printed part with a removable support member that slides or rolls relative to the horizontal worktable during the layer-by-layer deposition process.

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