Additive manufacturing stabilizer system and method

Abstract

Disclosed herein are systems and methods for the stabilization of additive manufactured or 3D printed parts. The stabilization system may comprise a frame with one or more stabilization mechanisms coupled to the frame. The stabilization mechanisms may be actuated via a motor or a clamping mechanism, and the clamping mechanism may be a four-bar linkage mechanism. Various stepper motors may be provided to actuate the movement of the print head and stabilization mechanisms. The stabilization system reduces print time and is reusable, providing advantages over conventional systems.

Description

SWCYC. OOIWO PATENTADDITIVE MANUFACTURING STABILIZER SYSTEM AND METHODINCORPORATION BY REFERENCE TO AN Y PRIORITY APPLICATIONS

[0001] This application claims the priority benefit of U. S. Provisional Application No. 63 / 720,540, filed November 14, 2024, the entire disclosure of which is incorporated herein by reference in its entirety as if fully set forth herein.BACKGROUND

[0002] Three-dimensional (3D) printing technology has revolutionized manufacturing and prototyping by enabling the creation of complex objects layer by layer. Despite its numerous advantages, 3D printing presents specific challenges, particularly when printing objects in the vertical direction. This challenge primarily arises due to the nature of the additive manufacturing process, where the printer builds objects from the bottom up. Vertical features, overhangs, and intricate geometries often require additional support structures to prevent collapse during printing.

[0003] Traditionally, to address this issue, practitioners in the field have employed support structures, which are auxiliary components printed alongside and structurally connected (bonded to) the main object. These support structures provide temporary scaffolding that holds up overhanging parts and prevents deformation or failure during the printing process. Support material is typically integrated into the printing process through specialized support generation algorithms, which are encoded into the G-code -a standard set of instructions used by 3D printers to execute printing tasks.

[0004] However, the conventional method of using support material introduces several limitations. Support structures are often designed to be removed after the primary object is printed, which can be a labor-intensive process. Moreover, the support material, once used, is typically discarded and not reusable. This results in increased material waste and operational costs. In addition, the removal of support structures can sometimes damage the primary object or leave undesirable marks or warping on its surface. In addition, the printing code may need to be modified to account for warpage or shrinkage based upon the different material compositions of support structures and build materials. The undesirable marks on thesurface of the 3D printed object can be particularly undesirable when the printed material is being optimized for reduced drag and optimized fluid dynamics.

[0005] In light of these challenges, there is a pressing need for advancements in 3D printing technology that address the difficulties associated with vertical printing and support structures. Specifically, solutions that minimize or eliminate the need for disposable support material, or support structures that are reusable, could significantly enhance the efficiency and sustainability of 3D printing processes. The present disclosure aims to address these issues by providing a novel approach to overcoming the limitations associated with vertical printing and object support throughout the printing process,SUMMARY OF SOME EXAMPLE EMBODIMENTS

[0006] Disclosed herein are embodiments of an additive manufacturing apparatus that can be used to print objects, including long and / or slender objects, without printed support structures. In some embodiments, the additive manufacturing apparatus can include a build plate, a frame with vertical and horizontal dimensions, a print head configured to dispense build material, a print head gantry coupled to vertical columns of the frame and configured to support and automatically move the print head relative to the frame, wherein the print head gantry has one or more motors, and one or more stabilizers attached to the frame and configured to move independently of the print head gantry, the one or more stabilizers each comprising: arms for engaging, disengaging, and supporting a printed object, one or more motors for movement in the vertical direction, wherein the one or more stabilizers and the print head gantry are coupled to the same stationary belts.

[0007] In any embodiment disclosed herein, each motor of the print head gantry and / or the one or more stabilizers can be coupled to a stationary belt for movement in the vertical direction. In some embodiments, the frame can have a vertical dimension at least twice that of the frame's horizontal dimensions, a print head coupled to the frame and configured to automatically move relative to the frame via a print head gantry, and one or more grippers configured to move relative to the print head and the frame. In some embodiments, the one or more grippers can include two arms coupled to the frame and extending from the frame in a horizontal direction. The two arms can be configured to move towards or away from each other. Two pliable gripper hands can be attached to the two arms.

[0008] In some embodiments of the additive manufacturing apparatus or methods, at least two stabilizers can be coupled to the frame and configured to move relative to each other in a vertical direction, wherein the motors of the at least two stabilizers can be coupled to the same stationary belts that the print head gantry’ is coupled to.

[0009] In some embodiments of the additive manufacturing apparatus or methods, the one or more stabilizers can have one or more rollers for engaging and supporting the printed object.

[0010] In some embodiments of the additive manufacturing apparatus or methods, the print head gantry can have four corners with motors in each corner, the one or more stabilizers have four corners with motors in each corner, and the frame can have four vertical columns with a stationary belt in each vertical column; wherein each corner of the print head gantry and one or more stabilizers can be attached to one of the four stationary belts.

[0011] In some embodiments of the additive manufacturing apparatus or methods, the frame can have a vertical dimension at least twice that of the frame’s horizontal dimension.

[0012] In some embodiments of the additive manufacturing apparatus or methods, the two arms can be configured to move relative to each other through a screw-driven four-bar linkage mechanism and the four-bar linkage mechanism can include a fixed frame, an input link connected to the fixed frame and driven by an external force or actuator to move in a horizontal direction, an output link connected to the input link that moves in coordination with a movement of the input link, and a coupler link that connects the input and output links and facilitates a transfer of motion between the input link and the output link.

[0013] In some embodiments of the additive manufacturing apparatus or methods, a portion of the stabilizer that touches and supports the printed object can be made from or can include rubber or foam.

[0014] In some embodiments of the additive manufacturing apparatus or methods, the print head gantry and the one or more stabilizers can connect to the frame via one or more linear bearings.

[0015] In some embodiments of the additive manufacturing apparatus or methods, the one or more stabilizers can each have one or more transverse motors for movement of the stabilizer arms, wherein the transverse motors are coupled to one or more stationary' belts.

[0016] In some embodiments of the additive manufacturing apparatus or methods, the build plate can be stationary.

[0017] In some embodiments of the additive manufacturing apparatus or methods, the stabilizers do not have any pressure or proximity sensors.

[0018] In some embodiments, the additive manufacturing apparatus can include a stationary build plate, a frame with vertical and horizontal dimensions, a print head coupled to the frame configured to automatically move relative to the frame by means of a print head gantry, and at least one parallel stage mechanism attached to the frame for stabilizing a printed object. In any embodiments disclosed herein, the parallel stage mechanism can include one or more rollers coupled to longitudinal sides of the parallel stage mechanism, and at least two motors for independently moving the longitudinal sides of the parallel stage mechanism in a horizontal direction toward and away from each other, at least two motors for moving the parallel stage mechanism on the frame in the vertical dimension, wherein the parallel stage mechanism is configured to move independently of the print head along the length of the vertical dimension.

[0019] In some embodiments of the additive manufacturing apparatus or methods, the frame can have a vertical height at least 150% of the frame's width or depth.

[0020] Also disclosed herein are embodiments of a method for stabilizing an object during additive manufacturing, the method including depositing one or more first layers onto a stationary build platform from a printing head coupled to a frame, determining that the one or more first layers exceed a threshold height, engaging a first or second stabilizer to support at least a portion of the one or more first layers, depositing one or more second layers on top of the one or more first layers, determining that the one or more second layers exceed a threshold height, and moving the remaining first or second stabilizer to support at least a portion of the one or more second layers, wherein the second stabilizer is vertically higher than the first stabilizer.

[0021] In some embodiments of the additive manufacturing apparatus or methods, the first and second stabilizers can engage the printed object with two or more rolling wheels.

[0022] Also disclosed herein are embodiments of a method for stabilizing an object during additive manufacturing, the method including depositing one or more first layers onto a stationary build platform from a printing head coupled to a frame, determining that the oneor more first layers exceed a threshold height, engaging a first or second stabilizer to support at least a portion of the one or more first layers, depositing one or more second layers on top of the one or more first layers, determining that the one or more second layers exceed a threshold height, and engaging the remaining first or second stabilizer to support at least a portion of the one or more second layers, wherein the first stabilizer is vertically higher than the second stabilizer. In some embodiments of the additive manufacturing apparatus or methods, the first and second stabilizers can engage the printed object with two or more rollers.

[0023] Some embodiments of the additive manufacturing apparatus or methods, additionally include depositing one or more third layers one top of the one or more second layers, determining that the one or more third layers exceed a threshold height, and engaging a third stabilizer at a vertical position higher than the second stabilizer.

[0024] Some embodiments of the additive manufacturing apparatus or methods, additionally including determining a threshold pressure for supporting the object via a pressure sensor on the first or the second stabilizer. In some embodiments, the method can additionally comprise determining the location of the widest dimension of the object at a vertical heigh and advancing a side of the stabilizer to support the material at that location

[0025] Some embodiments of the additive manufacturing apparatus or methods, the first stabilizer or second stabilizer are operably adjusted via a four-bar linkage mechanism including an input link connected to a support frame and driven by an external force or actuator to move in a horizontal direction, an output link connected to the input link that moves in coordination with a movement of the input link, and a coupler link that connects the input and output links and facilitates the transfer of motion between the input link and the output link.

[0026] Some embodiments of the additive manufacturing apparatus or methods, the four-bar linkage mechanism can be configured for manual adjustment throughout the printing process.

[0027] Some embodiments of the additive manufacturing apparatus or methods, the four-bar linkage mechanism can be configured for automatic adjustment via a processor configured to control the printing head and the first and second stabilizers.

[0028] Some embodiments of the additive manufacturing apparatus or methods, at least one of the first or second stabilizer has two horizontal support arms operatively connected to a single stepper motor for engaging and stabilizing the object.

[0029] Some embodiments of the additive manufacturing apparatus or methods, first stabilizer and second stabilizer can be configured to support a printed object with a vertical to horizontal dimension of at least 2:1.

[0030] Also disclosed herein are embodiments of a method for stabilizing multiple levels of a printed object, the method including depositing first layers, moving a first stabilizer vertically to a first region below the top of the first layers, actuating the first stabilizer to support the first region with one or more rollers, depositing second layers on top of the first layers, moving a second stabilizer vertically to a second region below the second region, actuating the second stabilizer to support the second region, depositing second layers on top of the first layers, disengaging the first stabilizer and moving the first stabilizer vertically in a disengaged position such that the first stabilizer does not roll along the part, reengaging the first stabilizer at second position that is vertically higher than the first position.

[0031] Also disclosed herein are embodiments of a method for stabilizing multiple levels of a printed object, the method including depositing first layers, moving a first stabilizer vertically to a first region below the top of the first layers, actuating the first stabilizer to support the first region, depositing second layers on top of the first layers, moving a second stabilizer vertically to a second region below the second region, actuating the second stabilizer to support the second region, releasing the first stabilizer and moving it vertically upward to a fourth region below the top of the second layers, actuating the first stabilizer to support the fourth region, releasing the second stabilizer and moving it vertically to a third region below the fourth region, and depositing third layers on top of the second layers.

[0032] Some embodiments of the additive manufacturing apparatus or methods, the first layers, second layers, and third layers each include a plurality of layers.

[0033] Also disclosed herein are embodiments of a method for stabilizing multiple levels of a printed object, the method including depositing first layers, moving a first stabilizer vertically to a second region that is vertically beneath the first layers, actuating the first stabilizer to support the second region, depositing second layers on top of the first layers, continuously moving the first stabilizer in a vertical direction while stabilizing the printed object with the first stabilizer.

[0034] In some embodiments of the additive manufacturing apparatus or methods, the first stabilizer can include a parallel stage mechanism with longitudinal and transversesides, rollers coupled to longitudinal sides of the parallel stage mechanism, and at least two motors for moving the longitudinal sides of the parallel stage mechanism in a horizontal direction toward and away from each other.

[0035] In some embodiments of the additive manufacturing apparatus or methods, the first stabilizer can be a roller stabilizer, and the method additionally includes actuating a second roller stabilizer in a first region that is vertically beneath the first stabilizer.Brief Description of the Drawings

[0036] Figure 1 illustrates an embodiment of a gripper mechanism according to some embodiments herein.

[0037] Figure 2 illustrates an embodiment of a top plan view of a gripper mechanism according to some embodiments herein,

[0038] Figure 3 illustrates an embodiment of a stabilization and printing system according to some embodiments herein.

[0039] Figure 4 illustrates a top plan view of the embodiment of the frame with one or more gripper mechanisms.

[0040] Figure 5 illustrates a side view of the frame with gripper mechanisms according to some embodiments herein.

[0041] Figure 6 illustrates a perspective view of a gripper mechanism according to some embodiments herein.

[0042] Figure 7 is a flow chart of an example method for stabilizing an object according to some embodiments herein.

[0043] Fig. 8 is a flowchart of an example method for stabilizing an object during additive manufacturing.

[0044] Fig. 9 illustrates a perspective view of an embodiment of a parallel roller stabilization system according to some embodiments herein.

[0045] Fig. 10 illustrates a perspective view of an embodiment of a parallel roller stabilization system attached to a frame.

[0046] Figure 11 illustrates a vertical cross-sectional view of an embodiment of a parallel roller stabilization system according to some embodiments herein.

[0047] Fig. 12 illustrates a side view of an embodiment of a parallel roller stabilization system according to some embodiments herein.

[0048] Fig. 13 illustrates a top plan view of an embodiment of a parallel roller stabilization system according to some embodiments herein.

[0049] Fig. 14 illustrates a front view of an embodiment of a parallel roller stabilization system according to some embodiments herein.

[0050] Fig. 15 illustrates a flow diagram according to some embodiments herein.

[0051] Fig. 16 illustrates a perspective view of an embodiment of the stabilization and printing system having a parallel roller stabilization system according to some embodiments herein.

[0052] Fig. 17 illustrates a side view of the embodiment of the stabilization and printing system having a parallel roller stabilization system according to some embodiments herein,

[0053] Fig, 18 illustrates a top plan view of an embodiment of the stabilization and printing system having a parallel roller stabilization system according to some embodiments herein.

[0054] Fig. 19 illustrates a top plan view of an embodiment of an engaged parallel roller stabilization system according to some embodiments herein.DETAILED DESCRIPTION

[0055] The methods and embodiments disclosed herein provide improvements over traditional additive manufacturing or 3D printing processes. Embodiments herein relate to a layer-by-layer manufacturing process and apparatuses. Some embodiments relate to large-format 3D printing technologies, specifically addressing the challenges of printing tall and slender objects. Traditional 3D printing methods require extensive support structures printed with or bonded to the object, leading to increased material usage, higher costs, extended print times, and environmental impact. These supports often result in structural instability and limit geometric complexity, reducing the options of objects that can be printed. The stabilizer system of some embodiments disclosed herein provides a novel solution by stabilizing prints without excessive material use, reducing print times, enhancing design freedom, and promoting sustainability in additive manufacturing.

[0056] In some embodiments, the stabilization systems can be configured to support and stabilize any vertically-oriented object during the 3D printing process, particularly those with a vertical-to-horizontal dimension ratio greater than 1:1. This system is especially beneficial for objects that exhibit a significant height relative to their width, which may present stability challenges during printing. By employing grippers or stabilization arms, the system can securely hold such objects, preventing tipping, deformation, or other issues commonly associated with tall, narrow printed parts. The stabilization mechanism can ensure that forces applied during printing, such as horizontal forces or material deposition forces, do not compromise the part’s structural integrity.

[0057] Examples of objects that benefit from this stabilization system include construction materials including without limitation doors, beams, and columns, and other objects that require relatively precise vertical alignment during fabrication. Additionally, the system can be used in aerospace applications, stabilizing tall, slender components such as fuselage sections, struts, or airfoils. Sporting goods, such as surfboards or other watersports boards, which have long vertical dimensions relative to their width, can also be printed with greater precision and integrity using this system. Further, the stabilization mechanism can be used for structural components. Moreover, the embodiments of the additive manufacturing apparatus disclosed herein can be used to print medical devices like prosthetic limbs and other objects that require support throughout the printing process. The versatility and adaptability of some embodiments of the apparatus disclosed herein make it well-suited for handling a wide range of vertically-oriented objects across various industries.

[0058] Since the stabilization systems in the disclosed printing and stabilization system are not bonded to the printed object and do not require post-print removal, the resulting object maintains a cleaner, more refined surface. This lack of bonded supports allows the object to retain its intended geometric accuracy and surface finish, thereby contributing to a more aerodynamic profile. In applications where fluid dynamics are critical, such as aerospace components or sporting goods (such as surfboards), the absence of support-removal artifacts enhances the object's aerodynamic performance by reducing drag and turbulence caused by surface irregularities. This results in improved efficiency and functionality in fluid dynamic environments.

[0059] The disclosed system enhances print stability by preventing warping and layer misalignment in tall and slender objects. By providing continuous support throughout the printing process, the system ensures that the printed part maintains its intended geometric accuracy, even in cases where the vertical dimension significantly exceeds the horizontal dimension. Additionally, the system allows for greater design flexibility and complexity by overcoming the geometric limitations typically encountered in traditional 3D printing processes. This enables the fabrication of intricate and complex structures that would otherwise be difficult to produce due to instability or deformation risks during printing.

[0060] Some embodiments of the stabilization systems disclosed herein enable the printing of vertical objects that would not be possible in traditional 3D printing. Advantageously, vertical objects may be printed in a single print job, reducing additional postprinting or post-processing. For example, some embodiments of the 3D printing support and / or stabilization systems disclosed herein increase the efficiency of printing an object having at least 2: 1 vertical: horizontal dimensions by at least 100%.

[0061] In some traditional processes, objects having 2:1 vertical horizontal dimensions are not able to be printed in a single printing process. In some conventional processes, portions of the object are printed and then later joined together in post processing steps. These joined layers may be weaker than layers printed by some of the embodiments of the printing systems disclosed herein. Therefore, there can be substantial benefits to printing a contiguous piece with 2:1 vertical: horizontal dimensions. The systems herein allow for contiguous printing of tall and slender objects.

[0062] The embodiments of the additive manufacturing apparatuses and methods disclosed herein may be applied to various forms of 3D printing, but extrusion-based and freeform printing methods are particularly applicable to the methods disclosed herein. As a non-limiting example, any layer-by-layer process that produces objects with a vertical to horizontal dimension greater than 1:1 may be benefited by the system disclosed herein. For example and without limitation, any of the apparatuses and methods disclosed herein may be applicable to objects having a vertical to horizontal (x or y) dimension greater than or equal to 1:1 or about 1:1, greater than or equal to 1.25:1 or about 1.25:1, greater than or equal to 1.5:1 or about 1.5:1, greater than or equal to 2:1 or about 2:1, greater than or equal to 3:1 or about 3:1, greater than or equal to 4:1 or about 4:1, greater than or equal to 5:1 or about 5:1, from1.5:1 or about 1.5: 1 to 5:1 or about 5:1, from 2:1 or about 2:1 to 4:1 or about 4:1, or any value, approximate value, or range of values m any of the foregoing ranges. Similarly, the methods and structures may apply to rounded objects having a length-to-diameter (L / D) ratio greater than 1.

[0063] One of the ad vantages of embodiments disclosed herein is the ability to print long, integrally connected structures in a 3D printed part. For example, in the case of printing a board or surfboard, the entire length (longest dimension) of the object can have a continuous outer shell or continuous inner scaffold, which increases the stress tolerance and durability of the 3D printed object. In some embodiments, the printed structures have an integrally connected (formed from a single printing procedure) vertical layer that is at least 1 m tall, at least 1.25 m tall, at least 1.5 m or approximately 1.5 m tall, at least 1,75 m or approximately 1.75 m tall, at least 2 m or approximately 2 m tall, at least 3 m or approximately 3 m tall, at least 4 m or approximately 4 m tall, or any value or range in between.

[0064] Some embodiments of the disclosed stabilization system are designed to be highly cost-effective, offering a reduction in cost of at least 50% compared to conventional stabilization systems. This cost efficiency is achieved through the use of simpler mechanical components and advanced control systems that minimize the need for complex or expensive hardware. / Additionally, some embodiments of the system significantly reduce the amount of material used during the 3D printing process, particularly in relation to printed support structures. By providing external stabilization, some embodiments of the system can eliminate the need for over 50% of the printed support material typically required to prevent part deformation or misalignment, resulting in both material savings and faster production times. For example, a part printed in the embodiment of the system 300, or m any of the embodiments herein, does not require and is not attached to printed support structure. In some embodiments, the article printed requires no post-processing for removing support structures. In some embodiments the printed article does not require any post-processing, reducing costs of the printed article. In some embodiments, only a single type of material is extruded from the print head, thus eliminating the need to extrude a different type of support material.

[0065] Figure 1 illustrates a gripper mechanism 100 (also referred to herein as a gripper) according to some embodiments herein. The gripper mechanism 100 includes two gripper hands 110 attached to two gripper arms 160. The gripper hands 110 may be pliablegripper hands. The gripper hands as shown have a degree of curvature, such as a parabolic degree of curvature. In other embodiments, the gripper hands may be straight or generally straight or have any other desired shape. The degree of curvature m the gripper hands can, in some embodiments, improve contact with a printed part, allowing the gripper hands to adjust to a curved surface. The pliability of the gripper hands may be a function of the degree of curvature or the composition of the gripper hands. In other embodiments the gripper hands are flat. In some embodiments, the gripper hands 110 are comprised of a rubber, foam material, or plastic. For example, and without limitation, the gripper hands 110 may be comprised of elastic plastic. In some embodiments, the gripper hands 110 may have a curvature that corresponds to or matches the curvature of the printed object. In some embodiments, the curvature of the gripper hands 110 may have the opposite curvature of the object being printed. For example, if the outside of the printed object has a positive curvature in the horizontal axis the gripper hands may have a negative curvature in the horizontal axis. The printed part may have a positive parabolic curvature, and the gripper hands may have a negative parabolic curvature. In some embodiments the gripper hands are at least two inches or about two inches long, at least three inches or about three inches long, at least four inches or about four inches long, at least six inches or about six inches long, at least ten inches or about ten inches long, at least a foot or about a foot long, or any number or range of numbers in between. The gripper hands 110 may be attached to the gripper arms 160 via hand fasteners 180. In some embodiments the hand fasteners 180 may be rigidly fixed to a certain location of the gripper arms. In other embodiments, the hand fasteners 180 may be attachable to the gripper arms 160 such that they can be adjusted along the length of the gripper arms 160. In this way the placement of the gripper hands 110 may be adjusted for the geometry of the part being printed. In some embodiments, the placement of the gripper hands on the gripper arms 160 may be automatically adjusted with one or more of a belt, pully, linear motor, etc. In this embodiment, the gripper hands 110 are attached to the gripper arms 160 via the hand fasteners 180 that have wheels, bearings, tracks, or other slideable and adjustable components.

[0066] The gripper arms 160 can extend from the gripper gantry 150 in a horizontal direction. In some embodiments, the gripper gantry 150 is attached to a larger frame or gantry via printer fixtures 120. The gripper arms can be coupled to the gripper gantry' 150 via a clamping mechanism 140. The clamping mechanism 140 is movable along the gripper gantry150 in the horizontal direction via a fixing mechanism 130. The fixing mechanism 130 may be manually or automatically adjusted or manually fixed in place. The position of the fixing mechanism 130 may be based upon the dimensions of the printed part, such as the vertical dimension of the fixing mechanism. The position of the fixing mechanism may also be determined in coordination with the position of one or more additional gripper mechanisms 100, either above, below, or on the same level as another gripper mechanism.

[0067] The clamping mechanism 140 may include a screw-driven four-bar linkage mechanism, such as shown in Figure 1. The mechanics of the screw-driven four-bar linkage mechanism are discussed below. The gripper arms 160 are movable at least in a horizontal direction, for example and without limitation, towards and / or away from each other. In some embodiments, the gripper arms 160 are also movable in a vertical direction. When actuated, the gripper arms 160 move towards each other to engage and stabilize the part. The actuation of the gripper hands 110 in a direction toward each other, the movement of the gripper gantry 150, and / or the movement of the gripper hands towards or away from each other may be accomplished automatically via wired stepper motors or manually via an operator. Preferably the gripper hands are automatically actuated to reduce need for an operator. The gripper arms 160 have a proximal portion (close to the frame) and a distal portion (further from the frame). The gripper arms 160 may have gripper hands 110 attached to either the proximal or distal portion of the gripper arms 160. In some embodiments, the gripper hands 110 are attached to the distal portion of the gripper arms 160.[ 00681 The gripper mechanism 100 may generally be comprised of 8020 aluminum extrusion, except the gripper hands 110 which may be comprised of a pliable material such as foam or rubber. Some of the joints of the gripper mechanism 100 may be comprised of plastic or metal, including additional components (not shown) that attach to the stepper motors, pulleys, bearings and electrical components. In some embodiments, portions of the gripper mechanism were printed in a 3D printer. In some embodiments, the additive manufacturing system applies a controlled or predetermined pressure to a three-dimensional (3D) printed object during printing or post- processing for stabilization. The pressure may be maintained within a threshold range of approximately 300 to 1,500 pascals (Pa), or sufficient to secure the object without inducing deformation or compromising dimensional accuracy. In some embodiments, the pressure threshold is about 300 Pa, about 400 Pa, about 500 Pa, about 600Pa, about 700 Pa, about 1,000 Pa, about 1,500 Pa, or any number or range of numbers in between.

[0069] The gripper arms 160 or gripper hands 110 may be equipped with one or more sensors (not shown), such as one or more pressure sensors, to determine a threshold pressure for stabilizing the part. In some embodiments, one or more sensors may be used for closed-loop control of the gripper mechanism, including the gripper arms 160 and / or gripper hands 110.

[0070] In the closed-loop mode, the system incorporates light or pressure sensors to actively monitor the position of the grippers at various heights during printing. These sensors provide real-time feedback, allowing for dynamic adjustments to the grippers’ position as the part is built layer by layer. The system may further include a software interface, enabling the user to adjust grip levels and Z-steps during the printing process. This interface allows for fine-tuning of the stabilization forces in response to real-time conditions, enhancing control over the printing process and ensuring optimal part stabilization at all stages of fabrication. In some embodiments, visual or light sensors detect vibrations during the printing process and adjust the stabilizer’s position accordingly.

[0071] The stabilization system may also operate in one or more open-loop modes. In an open-loop mode, the system may utilize a post-processing algorithm to determine the position of the stabilizers based on the properties of the 3D model, including geometry, material composition, and structural requirements. This predetermined approach allows for accurate placement of the grippers without real-time feedback, ensuring stable support throughout the printing process.

[0072] In some embodiments, the sensor(s) are provided with a stepper motor that drives the movement of the gripper arms 160 or the four-bar linkage mechanism 140. For example, in each gripper, a pressure and / or mechanical sensor can be integrated to provide feedback to the control software upon detecting contact with the printed part. In some embodiments, upon receiving a command to engage the part, the stabilizer can initiate a controlled closure of the grippers on both sides. In some embodiments, the grippers are configured to approach the part until contact is made and, in some embodiments, subsequently retract by a few millimeters, and then re-approach the part at a reduced velocity of approximately 5 mm / s. This re-approach continues until a predefined force threshold isachieved or a predetermined offset position, based on the initial contact, is reached. The predefined threshold may be determined via the stepper motor.

[0073] In some embodiments, a sensor is provided within the gripper hands 110. Examples of contact sensors that may be integrated into the contact surface of the gripper mechanism 100 include, but are not limited to, pressure sensors, proximity sensors, and strain gauges, etc.

[0074] Pressure sensors, such as capacitive or resistive pressure sensors, can be affixed to the gripping surface to measure the force exerted on the object upon contact. These sensors may be designed to detect a range of forces and can be coupled with the control system to ensure precise grip adjustments. In some embodiments the pressure sensor may be integrated with a stepper motor that actuates the gripper hands or four-bar linkage mechanism. In some embodiments the sensors may be wirelessly connected to a computer controlling the printing operation. In some embodiments proximity sensors are provided near point of contact for the gripper hands 110, such as at the end of curvature of a gripper hand 110.

[0075] In conjunction with pressure sensors, proximity sensors, such as capacitive or inductive sensors, may be utilized to detect the distance between the gripper and the object before physical contact is made. Capacitive proximity sensors can detect changes in the electric field caused by the presence of an object, while inductive proximity sensors may rely on the detection of printed metallic surfaces via changes in inductance. The combination of proximity sensors and pressure sensors can enable precise control over the gripping mechanism, ensuring both initial contact detection and force regulation during engagement with the printed object.

[0076] The sensor on the gripper hand 110 or in the gripper mechanism 100 may be a load cell sensor. Some examples of load cells are strain gauge load cells, S-type load cells, piezoelectric load cells, or capacitive load cells. The load cells can determine compressive force to determine if a threshold pressure has been met or the load cells can determine a compressive position offset, taking into account the pliability of the foam or rubber pad in the gripper hands 110.

[0077] A strain gauge load cell can be affixed to the gripping mechanisms of the robotic arm to detect the applied force during contact with the printed part. This type of load cell offers high accuracy in force detection, which is essential for ensuring gentle handling ofparts, and is capable of measuring both tension and compression forces, providing versatile feedback during various operations. Additionally, its cost-effectiveness and compact design facilitate easy integration into the robotic system.

[0078] An S-type load cell may be integrated into the mechanical linkage between the gripper hands 110 and other portions of the gripper mechanism 100, for example in a linkage or other component, allowing for dual-function measurement of both compression and tension, making it particularly durable and suitable for varying loads imposed by different 3D-printed materials.

[0079] Piezoelectric load cells, which may be attached to the contact surfaces of the robotic arm, detect pressure applied during part engagement. These sensors excel in detecting rapid or dynamic force changes, providing real-time feedback, and are highly sensitive, enabling precise handling of delicate parts. Furthermore, capacitive load cells, integrated into the gripper mechanism, can measure both proximity and pressure, allowing the system to detect when it nears the part and when contact occurs, making them ideal for low-force applications and delicate material handling. Thus, piezoelectric sensors can be advantageously used to convert mechanical pressure into electrical signals, providing real-time feedback on the force being applied by the gripper.

[0080] Advantageously, the gripper mechanisms disclosed herein can provide a low-cost solution to support printed objects that could be stabilized. For instance, the cost of the frame and gripper mechanism 100 in some embodiments disclosed herein are at least an order of magnitude less expensive than the cost of other reusable supports systems, such as a six-axis robot configured to support multiple layers throughout the build process.

[0081] Figure 2 is a plan view of the gripper mechanism 100 shown in Figure 1. Different portions of the four-bar linkage mechanism 140 are shown as well as certain lengths 210 (solid lines) and an adjustable length (dashed line 220). The joints of the four-bar linkage mechanism 140 are configured so the sides of the four-bar mechanism move in parallel planes. Fixing mechanism 130 can be movably coupled on the gripper gantry 150 such that the fixing mechanism is able to be moved and reattach along the length of the gripper gantry 150. The four-bar mechanism comprises four rigid bars connected via joints or pivots, the four rigid parts including a fixed piece (fixing mechanism 130), an input link 240, a first output link 230,and a second output link 250. In some instances, the four- bar mechanism may be jointly connected to multiple output mechanisms.

[0082] Input link 240 is provided in the center of the four-bar linkage mechanism 140. The input mechanism (input link 240) may be screw-driven or automatically actuated (moved) with a stepper motor. The distance between the input link 240 and the fixing mechanism 130 is variable, indicated by the dashed line 220 between input link 240 and fixing mechanism 130. This adjustable length is indicated with distance Li. The movement of input link 240 adjusts the distance Li and brings about movement of output mechanisms, first output link 230 (or connector link) and second output link 250, Thus, when the distance between the input link 240 and the fixing mechanism 130 is smaller, the distance between the gripper arms 160 is smaller. When the distance between the input link 240 and the fixing mechanism 130 is larger the distance between the gripper arms 160 is larger. In the movement of the input link 240, the different components of the four-bar mechanism may move relative to each other. This structure is reliable and a low-cost approach to providing support for the printed object. This type of parallel four-bar linkage mechanism may be termed a dual four-bar gripper or dual four-bar claw.

[0083] One of the advantages of the stabilizer mechanism, particularly when employing a four-bar linkage mechanism, is its ability to apply equal mechanical pressure to both sides of the printed part. The symmetrical movement of the linkage ensures that the force exerted by the grippers is evenly distributed, preventing uneven pressure that could distort or misalign the part during stabilization. This balanced application of force maintains the part in the correct position throughout the printing process, ensuring that it remains securely supported without compromising its structural integrity or dimensional accuracy. In some embodiments the equal pressure on both sides of the printed part is maintained as the printed part is provided in the middle of the four-bar linkage mechanism.

[0084] Figure 3 illustrates a frame with gripper mechanisms according to some embodiments herein. The frame 360 surrounds the print area on all faces: top, bottom, and sides.

[0085] In some embodiments, the frame 360 contains a plurality of linear bearings. In some embodiments, the linear bearings are at least one of a ball bearing, a roller bearing, a plain bearing, or a linear guide. Linear bearings may include ball bearings, roller bearings,plain bearings, or linear guides. A ball bearing may utilize balls to reduce friction between the moving parts and the rail or shaft. A roller bearing may use cylindrical rollers instead of balls, often providing higher load capacities. A plain bearing may also be known as a sleeve bearing or bushing and may use a sliding motion without rolling elements, relying on lubricants to reduce friction. A linear guides may consist of a rail and a carriage with bearings, often used in conjunction with ball or roller elements. In at least one embodiment, the frame includes a plurality of linear bearings.

[0086] In some embodiments, the frame 360 includes a plurality of aluminum extrusion members (e.g., from 8020 aluminum) and may have joints made from plastic or metal. In some embodiments, the frame contains Misumi 8020 Base 20 aluminum extrusion, MGN9H linear rails, and 6082RS ball bearings.

[0087] In some embodiments, the frame 360 can have a height between about 250 mm and 5 meters. The frame 360 can have dimensions (length x width x height) of 250x125x250 mm to 1000x500x2000 mm or about 250x125x250 mm to about 1000x500x2000 mm. In some embodiments, the frame 360 has a dimension of about 250x125x250 mm, about 500x250x750 mm, about 500x250x1000 mm, about 500x250x1500 mm, about 500x250x2000 mm, or any value or range of values in between. In some embodiments, the frame may have a height of at least 1 meter or at least about 1 meter, at least 1.5 meters or at least about 1.5 meters, at least 2 meters or at least about 2 meters, at least 3 meters or at least about 3 meters, at least 4 meters or at least about 4 meters, at least 5 meters or at least about 5 meters, or of any value, approximate value, or range of values in any of the foregoing ranges. In some embodiments, the vertical height of the frame 360 is in the range of 250 mm to 4000 mm. In some embodiments, the frame is a triangular frame that is peaked at the top. The build plate area or base of the frame in horizontal directions (x-y) can range from about 250x250 mm to 2000 mmx2000 mm.

[0088] A print head gantry 340 may be coupled to the frame 360. The print head gantry' 340 is vertically movable in the printing of the object. The print head gantry' 340 is automatically adjusted vertically with the g-code (build code). The print head 350 is automatically adjusted on the print head gantry 340 in order to move in a horizontal direction to print layers in an x-y axis on the build plate 305 or above the build plate 305. In some embodiments, the print head 350 can be an extrusion-based print head. For example, the printhead 350 may be a print head configured for fused filament fabrication (FFF). Fused Filament Fabrication (FFF) is an additive manufacturing process that utilizes a continuous thermoplastic filament, which is heated and extruded through a nozzle to deposit material layer by layer, forming a three-dimensional object. The filament may be made of polymers such as PLA, ABS, or PETG, though other materials such as composites. However, fiber reinforced (such as carbon fiber reinforced fibers) and metal-infused filaments can also be used. FFF, sometimes referred to as Fused Deposition Modeling (FDM), is distinguished by its simplicity, low cost, and versatility m material usage.

[0089] Other types of printing may be employed in any of the embodiments of the additive manufacturing apparatus disclosed herein, or the print head 350 may be configured for other types of printing, such as freeform printing or direct ink writing. Freeform printing generally refers to a three-dimensional printing process in which material is deposited layer by layer, without the need for printed support structures and sometimes without the need for continuous stabilization, allowing for the creation of complex geometries with minimal constraints. In this method, the material, typically a thermoplastic, resin, or composite, is extruded in a controlled manner to build objects directly from a digital model. The absence of support structures reduces post-processing time and material waste, while enabling the fabrication of intricate, organic, or non-planar shapes that are difficult or impossible to achieve with traditional additive manufacturing techniques. Freeform printing is particularly beneficial in applications that require highly customized or irregular designs, such as biomedical implants or architectural components, where precision and flexibility are critical.

[0090] Some embodiments of the additive manufacturing apparatus disclosed herein may be configured for Direct Ink Writing (DIW). DIW generally refers to an extrusion-based additive manufacturing technique in which viscous inks, such as pastes, gels, or other semi-liquid materials, are deposited through a nozzle to create a 3D object. Unlike other extrusion-based techniques, DIW allows for the use of a wide range of materials, including ceramics, biomaterials, and conductive inks, providing flexibility for applications in fields such as electronics, tissue engineering, and soft robotics. One of the key benefits of DIW is its ability to process materials with high viscosity or shear-thinning properties, enabling precise control over the material deposition. Additionally, DIW enables multi-material printing, allowing for the creation of functionally graded structures or integrated systems. Thetechnique also allows for the direct deposition of inks onto various substrates, providing versatility in the fabrication of complex or hybrid structures.

[0091] Thus, the stabilization and printing system 300 may be adapted for any type of printing application where stabilization may be beneficial. The print head 350 may be movable on the print head gantry 340 in more than just the x-y axis, such as a print head 350 with multiple degrees of freedom.

[0092] The print head 350 may be configured to print filaments with a filament diameter of about 1.75 mm. In some embodiments, the print head 350 may be configured to extrude materials with a diameter of at least about 0.5mm, at least about 1mm, at least about 1.5 mm, at least about 2 mm or any value or range of values in between. The print head may also be configured to perform large-scale printing, such as extruding materials with a diameter of at least 1 cm, at least 5cm, at least 10 cm, at least 30 cm, at least 50cm, or any value or any range of values in between.

[0093] The print head 350 may be equipped with various nozzle sizes depending upon the particular printing application. In some embodiments, the dispensing nozzles diameters are in a range from 0.4 mm to 1.2 cm. In some embodiments, such as large-scale printing, the nozzle diameter is at least about 1cm, at least about 5 cm, at least 10 cm, at least 30 cm, at least 50 cm, or any value or any range of values in between.

[0094] The print head 350 may be configured to print filaments comprised of PETG, Nylon, ABS, or PLA, as well as fiber reinforced versions of these filaments such as fiber reinforced PETG, fiber reinforced Nylon, fiber reinforced ABS, or fiber reinforced PLA. The print head 350 may also be configured to print expanding foam filaments comprised of PE TG or PLA.

[0095] In the embodiment of the additive manufacturing stabilization and printing system 300 shown in Figure 3, several gripper mechanisms are provided, a first gripper 310, a second gripper 320, and a third gripper 330. Each of the first gripper 310, the second gripper 320, and the third gripper 330 may be manually or automatically adjustable m the vertical direction. Although the grippers (310, 320, and 330) are shown on a single side of the frame 360, one or more may be provided on opposite sides of the frame, so that they are across from each other. Thus, the gripper mechanisms can provide stabilization from more than one side of the object. In some embodiments, there is a minimum of one gripper and a maximum offour grippers in the stabilization and printing system 300. In some embodiments, there is a minimum of one gripper and a maximum of five grippers in the stabilization and printing system 300. In some embodiments, there can be any number of grippers suitable for stabilizing the printed part, including six, seven, or more grippers. In some embodiments the grippers or stabilizers are provided at the lowest vertical position in the frame 360 when the printing begins. As the printing progresses the grippers or stabilizers are advanced sequentially as the object is printed in the vertical direction. Alternatively, a new stabilizer is attached to the frame 360 each time Nth number of layers are printed, thus reducing serial movements of stabilizers as the part is printed,

[0096] Each of the first grippers 310, second gripper 320, and third gripper 330 may be primarily positioned within a region of the frame. For example, the first gripper 310 may be movable within a lower region of the frame, the second gripper 320 may be movable within a middle region of the frame, and the third gripper 330 may be movable within an upper region of the frame. In some embodiments, the first gripper 310, second gripper 320, and third gripper 330 are initially positioned substantially adjacent to each other in the lower, middle, or upper portion of the frame. For example, the grippers each may move nearly the entire vertical length of the frame 360 but are maintained below the print head gantry 340 in order to stabilize the printed layers below the print head gantry. The first gripper 310, second gripper 320, and third gripper 330 may be engaged or released and reengaged with the printed part in various orders, as discussed herein. Multiple layers of a printed object can be supported with two or more grippers, as discussed herein. In some embodiments the print head attachment or print head gantry 340 is on a different or distinct side of the frame from the grippers such that the print head can move past one or more grippers in a vertical direction as the print head 350 prints the object in a vertical direction.

[0097] The printer frame 360 may be coupled or attached to various stepper motors (not shown) to automatically actuate the movement of various stabilizers or gantries. In some embodiments, the grippers (for example and without limitation, grippers 310, 320, 330), print head 350, or print head gantry 340 are coupled to LDO Stepper Motors or Moon Stepper motors. In some embodiments, each gripper mechanism 100 is moved or driven by an individual, respective stepper motor. In some embodiments, each gantry in the system is moved or driven by an individual, respective stepper motor. In some embodiments, the systemcan include belts and pulleys, such as 9 mm wide GT2 belts or 9 mm pulleys, to move the grippers, print head, and / or gantry. In some embodiments, the rails of the printer frame 360 are MGN9H linear rails.

[0098] The movement of the grippers (310, 320, 330) may be configured for the speed of printing. In some embodiments, the grippers move vertically up to a speed of about 100 mm / s. In some embodiments, the grippers move vertically at a speed of about 50 mm / s, about 70 mm / s, about 90 mm / s or any value or range of values in between.

[0099] The stabilization and printing system 300 may be equipped with one or more processors or microprocessors configured to execute print code and configured to vertically adjust one or more grippers. In some embodiments, one or more processors are configured to calculate a distance or threshold between the one or more grippers. In some embodiments, one or more processors are configured to calculate a threshold distance between one or more grippers and the uppermost printed layer. The one or more processors may be configured to calculate a maximum distance between a gripper and the uppermost printed layer and execute a command to move one or more grippers vertically upwards when the threshold is exceeded. The threshold can be calculated based upon the object dimensions, the printed material composition, the solidification time of the material, and / or the vertical location of the uppermost printed layer or several layers.

[0100] The processors can be configured to control the positioning and gripping strength of the grippers based on various factors related to the printed part and the 3D printing process. For example, the processors can be configured to dynamically adjust the position of the grippers in response to the geometry of the printed part. By analyzing the shape, contours, and dimensions of the part, the system determines optimal gripping locations that ensure proper stabilization without damaging the part. For example, if the printed part includes overhangs or irregular surfaces, the processor adjusts the gripper’s position to support these overhangs or to avoid irregular areas (undulations, etc.) while still providing adequate support. In addition to geometry, the processor evaluates the distance between the gripper and the uppermost printed layer, ensuring that the grippers avoid interference with ongoing printing operations, particularly in areas where new layers are being deposited.

[0101] To prevent damage to structurally weak sections or overhangs of the printed part, the processor may analyze potential weak spots based on the part’s design and materialcomposition. In cases where overhangs or thin structures are present, the gripping force may be reduced or modulated to prevent excessive pressure. The system also considers the distance between individual grippers. If multiple grippers are used in close proximity, the processor coordinates their movements to ensure they do not apply excessive force or cause deformation in the part, particularly in delicate areas. The processor may be configured to ensure a balanced distribution of force across multiple grippers, optimizing stability while minimizing the risk of stress concentration.

[0102] Moreover, the composition and strength of the material used in the part, especially once it solidifies, is considered by the processor when determining gripping strength. For parts made of materials with lower tensile strength or those that are brittle upon solidification, the processor reduces the gripping force to avoid cracking or fracturing. Conversely, for parts composed of stronger, more durable materials, the processor may apply greater force for enhanced stabilization. The number of grippers in the system is also taken into account, as the processor calculates the appropriate force for each gripper based on the load distribution across the multiple gripping points. As the number of grippers increases, the force applied by each individual gripper may be distributed between buffer zones or reduced to ensure even distribution and to prevent overloading any single contact point or region.

[0103] In one method, the processor is configured to control the grippers by first receiving data regarding the geometry and material composition of the part to be printed. The processor analyzes this data to determine the optimal gripping positions and calculates the initial gripping force for each gripper. As the part is being printed, the processor monitors the position of each gripper relative to the uppermost printed layer and adjusts the grippers’ positions in real-time to avoid interference with the printing process. The processor further adjusts the gripping force in response to detected weak spots or overhangs in the part, applying less force to fragile areas and more force to structurally strong regions. Throughout the stabilization process, the processor coordinates the movements of all grippers to ensure that the distance between grippers is maintained within a safe range, preventing deformation or excessive force on any single section of the printed part.

[0104] In some embodiments, a micro process on board the stabilizer gantry controls the positioning and gripping strength of the grippers on the part based on previously tuned parameters. The parameters may be at least one of: the composition of the grippingsurface (such as the gripper hands), the geometry of the gripping surface (such as a parabolic curve), the material being printed, the geometry of the part being printed, the height of the part being stabilized, and the stepper motor speed.

[0105] Figure 4 illustrates a top plan view of the frame 360 with one or more grippers. The gripper hands 110, gripper arms 160, and clamping mechanism 140 are visible below the print head 350. As discussed herein, these components are coupled and adjustable on a frame 360. For example, each of the components are moveable on the frame via one or more motors, pulleys, belts, or automatic movement mechanisms.

[0106] Figure 5 illustrates a side view of the frame with gripper mechanisms according to some embodiments herein. As with Figure 3, this depicts a first gripper 310, second gripper 320, and third gripper 330 in series. The grippers may be set in a perpendicular orientation to the largest horizontal axis of the movable print head gantry 340 (for example, the y-axis shown in Figure 4),

[0107] Figure 5 depicts the vertical dimensions of the frame (z-axis), illustrating that the frame is generally configured with larger height in the vertical direction (e.g., along the z axis) as compared to either horizontal dimension (e.g., along either the x or the y axis). In some embodiments, the ratio of the vertical dimension of the frame or assembly (e.g., in the z direction) to the width or depth dimension of the frame or assembly (e.g., in the y direction or the x direction, respectively) can be at least 1:1 or approximately 1:1, or can be 4:1 or approximately 4:1, or can be 5:1 or approximately 5:1, or can be 6:1, approximately 6:1, or greater than 6: 1, or can be from 4: 1 or approximately 4: 1 to 8: 1 or approximately 8: 1, or from 4: 1 or approximately 4: 1 to 6: 1 or approximately 6:1, or of any values, approximate values, or ranges of values in any of the foregoing ranges. In some embodiments, grippers (such as 310, 320, 330) may be provided for each multiple of the vertical dimension to the largest horizontal dimension. For example, in some embodiments, 3 grippers may be provided where the vertical to horizontal dimension is approximately 3:1 or 4 grippers may be provided where the vertical to horizontal dimension is approximately 4:1.

[0108] Figure 6 illustrates a perspective view of a gripper mechanism 100 according to some embodiments herein. Figure 6 illustrates the gripper mechanism 100 shown in Figure 1 at a different perspective angle. Figure 6 shows a plain view of the fixing mechanism 130 as well as the printer fixtures 120.

[0109] Other gripper mechanisms can be used with any embodiments of the additive manufacturing devices disclosed herein. For example, the gripper mechanism may alternatively or additionally include a pneumatic gripper and / or a vacuum gripper. A pneumatic gripper can employ air pressure to create a firm yet adjustable grip on the printed part. The pneumatic system allows for fine control over the gripping force by varying the pressure applied, making it ideal for handling parts with fragile or intricate geometries. A vacuum gripper can utilize suction to stabilize the part by creating a pressure differential between the gripping surface and the part. Vacuum grippers are particularly effective for handling parts with large, smooth surfaces, as they can in some embodiments generate a strong holding force without causing significant localized stress. Vacuum grippers can be beneficial in minimizing surface damage, as they do not rely on direct clamping forces. Furthermore, their adaptability to various shapes and surfaces makes them highly versatile in multi-material 3D printing applications.

[0110] Fig, 7 is a flowchart of an example method for stabilizing a printed part. At step 710, the printer starts and deposits a base layer. At step 712, the tool head or printing head reaches layer A, which may be a layer deposited after a series of layers. At step 714, a first stabilizer (stabilizer 1) vertically moves from an initial or zero position of the first stabilizer to a first position of the first stabilizer that is below layer A (A minus buffer, wherein the buffer is the amount of space needed to avoid contact or impact with the print gantry or the amount of space capable of supporting the object, such as where layers are not yet dried / solid). In this position, the first stabilizer can stabilize the region associated with the first position of the first stabilizer. At step 716, the first stabilizer is actuated to stabilize one or more layers within a first region that is below layer A (layer A minus buffer).

[0111] In this scenario, a second stabilizer is utilized to provide stabilization to free up the first stabilizer, in order to stabilize additional higher layers. Step 718 involves a second stabilizer (stabilizer 2) being moved from the initial position of the second stabilizer to a first position of the second stabilizer that is just below the first stabilizer (Layer A minus buffer minus buffer2, where buffer 2 is a predetermined gap between the first and second stabilizer). In step 720, Stabilizer 2 is actuated to support one or more layers in a region corresponding to this first position of the second stabilizer. As discussed herein, each stabilizer may be actuated up until a certain pressure threshold, which may be determined by a pressure sensor. Theapparatus continues to deposit additional layers (step 722) up to an “Nth” layer. In some embodiments, step 722 of deposition of additional layers may be performed before step 718 is performed, after step 720 is performed, or both.

[0112] In step 724, the stabilizer 1 is released from stabilizing the region of the part associated with the first position of the first stabilizer (layer A minus buffer) and is moved vertically upward to a second position below the Nth layer (Nth layer minus buffer). In step 726, the first stabilizer is actuated to stabilize the region of the part associated with the second position of the first stabilizer, which is vertically higher than the region associated with the first position of the first stabilizer or the region associated with the first position of the second stabilizer.. In step 728, stabilizer 2 is released from the first position of the second stabilizer and moves vertically to a second position of the second stabilizer that is just below the first stabilizer (Nth layer minus buffer minus buffer 2). The second position of the second stabilizer is vertically lower than the second position of the first stabilizer but vertically higher than the first position of either the first or the second stabilizer. In step 730 stabilizer 2 is actuated to support the region of the part associated with the second position of the second stabilizer. Step 722 to step 730 may be repeated one or more times until the print is finished at step 732, Thus, as depicted in Figure 7, the stabilizers are sequentially moved vertically upwards to support the part as the part is printed in the vertical direction. The highest stabilizer is maintained below the print head below a buffer zone and stabilizer below the highest stabilizer is maintained below the highest stabilizer while allowing a buffer zone between the two stabilizers.

[0113] Fig. 8 is a flowchart of an example method for stabilizing an object during additive manufacturing. At step 810, the method includes depositing one or more first layers onto a stationary build platform from a printing head coupled to a frame.

[0114] At step 820, the method includes determining that the one or more first layers exceed a threshold height. The threshold height may be determined based upon the material that is printed (its melt / solidification characteristics), the geometry of the printed part (more stabilization for irregular patterns or potential overhands), the speed of printing, the width of the printed part, the weight of the printed part, or a combination of the above.

[0115] At step 830, the method includes engaging a first stabilizer to support the previously deposited one or more first layers. At step 840, the method includes depositing one or more second layers on top of the one or more first layers. At step 850, the method includesdetemiining that the one or more second layers exceed a threshold height. At step 860, the method includes engaging a second stabilizer to support the one or more second layers, wherein the second stabilizer is engaged in a vertical position higher than the first stabilizer.

[0116] Fig. 9 illustrates a perspective view of a parallel roller stabilization mechanism 900 according to some embodiments herein. The mechanism 900 may be movably coupled to the vertical rails of a gantry, such as frame 360. The parallel roller stabilization mechanism 900 includes at least two rollers 910 on opposing sides of the mechanism 900. In some embodiments, the mechanism 900 has at least one roller 910, or in other embodiments at least two rollers, or at least four rollers, or at least six rollers, or at least eight rollers, or at least ten rollers on each side. Importantly, in some embodiments, the rollers are provided in coaxial alignment, straight line such that one roller, one or more rollers, two rollers, two or more rollers, or three or more rollers on each side engage the part at the same time. In some embodiments a single roller is provided on each side in order to provide a single continuous surface for contacting the printed part. In some embodiments, the roller mechanism 900 is provided with six rollers, three on each opposing side, for supporting the printed object. Having at least two rollers or at least three rollers on each opposing side may be advantageous for supporting large, printed objects, such as surfboards or long structural objects in order to provide a support surface along the entirety of the printed object, such as the entirety of the width of the part. Rollers 910 also advantageously provide continuous support for the printed object and can move independently of the print head, either vertically along the height of the printed object or horizontally toward and away from the printed object.

[0117] In some embodiments, the rollers 910 on each side can be configured to roll independently of each other. Additionally, the rollers 910 are configured such that a non- rolling structure (bracket, bar, etc.) does not extend past the rolling surface. The rollers 910 are adjacent to each other with minimal space between the end of the roller and the beginning of the next roller, which allows optimal support for the printed object. Additionally, providing two or more roller surfaces allows rolling to be tailored to each section of an object.

[0118] In some embodiments, the rollers are configured to engage a part at a vertical height and then disengage from the part before they are moved to a different vertical height. Disengaging the reengaging the printed part with the rollers 910 allows linear contact with a discrete portion of the printed part, and not continuous contact with the printed part. Forexample, the stabilizers (parallel roller stabilization mechanism 900) can be configured to contact vertical portions of the part (a layer or a group of layers) in an open loop manner, taking into account the geometry of the printed part at each vertical height. Thus, by engaging and disengaging the rollers 910 from the part, the open loop system is only required to contact the outermost surface at a particular vertical height and is not required to continuously calculate the outermost layer of the part as the rollers 910 continuously move up the printed part. Additionally, having linear contact with a printed part (at a particular vertical height) allows for less variation in the pressure exerted on the surface of the printed part. For this reason, linear support components (such as flat gripper hands, flat edges of edge wedges, or rollers) can be used as the portions that engage the printed part.

[0119] In the illustrated embodiment, the rollers 910 are attached to a longitudinal rail 920 via roller attachments 950. The longitudinal rail 920 may also be termed “arms” of the stabilizer or arms of the parallel roller stabilization system. The roller attachments 950 are shown as brackets that connect one or more rollers to the longitudinal rail 920. The roller attachments 950 may contain brackets with solid connectors such as screws. In some embodiments, one or more other fasteners can used to couple the roller attachments 950 to the respective rail 920. Alternatively, the roller attachments may be removably coupled to the longitudinal rail 920 via clips, snaps, buttons. Velcro, or other removable fasteners.

[0120] The longitudinal rail 920 is movably coupled to transverse rails 930 via transverse motors 940. Transverse motors 940 can be stepper motors or servo motors with wheels or rolling components that are configured to move along the transverse rails 930. The transverse motors 940 enable the rollers 910 to move toward and away from each other on the horizontal plane to support the object as it is being printed. In some embodiments, there are four transverse motors 940, two for each side having a longitudinal rail 920. In some embodiments, there are only two transverse motors 940, one on each side having a longitudinal rail 920. In some embodiments, the transverse motors can operate independently of one another to permit the independent movement of each longitudinal rail 920. The longitudinal rail 920 may also be referred to as “arms” that move to engage or disengage the object, similar to the gripper arms mentioned above.

[0121] The transverse motors 940 can be controlled to move the rollers 910 toward or away from each other based upon the 3D CAD file, such as an STP file, in an open loopmanner as discussed herein. Additionally, or alternatively, transverse motors 940 can be controlled to move toward each other based upon a proximity sensor or a pressure sensor in a closed loop manner. For example, the rollers 910 may be configured to engage the printed object up until a predetermined pressure threshold, the pressure being determined by a pressure sensor as discussed above. The pressure sensor may be a capacitive pressure sensor that is embedded into the rollers 910, roller attachments 950, or transverse motors 940. The pressure sensor may also be a resistive pressure sensor with load cells near the attachment of the rollers to the longitudinal rails. Alternatively, the pressure sensor may be provided within the transverse motor 940, The pressure sensor may be configured to provide a closed feedback loop to the transverse motors 940 to reduce engagement of the rollers 910 on the printed object up until a certain pressure threshold is reached. The pressure sensor may also include one or more proximity sensors in order to gauge distance to the printed object prior to or during engagement of the rollers 910.

[0122] Another embodiment includes one or more springs attached to the roller attachments 950 in order to provide a compliant mechanism to absorb pressures on the printed object. Alternatively, the rollers 910 may be collectively tension loaded via a spring m order to maintain equal contact on the printed object between the rollers 910. For example, a spring may maintain a force between each longitudinal side.

[0123] In some embodiments, the stabilization mechanism 900 additionally includes one or more vertical motors 960 for movement of the stabilization mechanism 900 in the vertical axis, with movement being independent of the print head. The vertical motors 960 for the stabilizers may maintain the stabilization mechanism at a predetermined distance from the print head while not being coupled or tethered to the print head and still being able to move independently of the print head. The vertical motors 960 attach to a gantry or frame, such as frame 360 mentioned above. In at least one embodiment, there are four vertical motors 960, each on a corner of the parallel roller stabilization mechanism 900. The vertical motors 960 can be stepper motors or servo motors. In some embodiments, in each corner, the vertical motors 960 (stepper motors) can move along a single, stationary belt routed along the z-axis of the frame to provide synchronized vertical motion. The printhead 340 can also contain vertical motors in each of the four corners of the print head gantry 340, similar to the stabilization mechanism 900. Thus, the vertical motors 960 of the stabilization mechanism 900and the vertical motors of the printhead 340 are attached to the same bars of the frame 360 and the same vertical belt in each of the four corners. In some embodiments there are at least two print head gantries 340 attached to the frame 360 in addition to one or more stabilizer gantries. In some embodiments a static lead screw or a gear track may be provided as an alternative to a stationary belt for the movement of the vertical motors along the vertical length of the frame 360.

[0124] In some embodiments, the frame 360 may include or be made from 40x40 extruded aluminum, as discussed above. The printhead gantries and stabilizer gantries can be configured to attach to the frame via one or more carriages that are slotted into tracks in the frame 360. The carriages may be provided on a single track in the vertical members of the frame, or the carriage may be attached to and slide along dual tracks that are provided in the vertical members of the frame. Linear bearings may be provided on the carriages in order to facilitate vertical movement of the carriages along the frame 360. The linear bearings may be BEAR-MGN12H linear bearings. As an alternative, the carriage may attach directly to a rod of the frame 360 and not be coupled to a track in the frame 360. An embodiment of a carriage attachment member 970 is illustrated in Figure 9 (four carriage attachment members 970 being shown) that attach to the carriages on the frame 360.

[0125] Figure 10 illustrates an expanded view of the attachment of the parallel roller stabilization mechanism 900 to the frame 360. Although only a single corner is depicted in Figure 10, each of the corners of a print head gantry or a stabilization gantry may be provided with similar or identical components. In some embodiments, the system beneficially has four vertical motors in each gantry attached to the frame 360 that are movable on the same vertical rails and the same stationary vertical belt 1010. This reduces space in the frame 360, as each vertical motor is not required to have its own belt system. As a result of each of the vertical motors being movable on the same frame, the system can print taller objects within the same frame 360. In some embodiments, at least 4 vertical motors, at least 8 vertical motors, at least 12 vertical motors, or at least 16 vertical motors are movable on the same stationary vertical belt or the same vertical members of the stationary’ frame 360.

[0126] In some embodiments, the stationary vertical belt 1010 has teeth or cogs on one side thereof that engage with a gear or teeth of the vertical motors 960 so that the vertical motors 960 (e.g., without limitation, a gear of the vertical motors 960) can engage the belt andmove in the vertical direction. Thus, the vertical motors 960 can be moved up and down the vertical axis. Similarly, in some embodiments, a stationary horizontal belt 1020 can be provided for the movement of the transverse motors 940 in the horizontal or transverse direction. This belt can also have notches or teeth so the stepper motors of the transverse motors 940 can move in the horizontal direction with high fidelity. The belt may be a GATES-LL-2GT GT2-6mm timing belt with a width of 6mm or 10mm having glass fiber reinforced neoprene black (Model number GT2(2GT)). The distance between the teeth on the belt may be optimized for fine adjustments of the transverse motors 940 along the transverse rails 930.

[0127] The motors can be controlled with a closed feedback loop program based upon feedback from proximity sensors and pressure sensors in the mechanism 900 or the motors can be controlled with an open feedback loop program with the print head and printing file in order to prevent excess force on the printed object. The mechanism 900 may also include one or more vertical proximity sensors to gauge the distance to the print head and maintain a predetermined distance to the print head. The vertical proximity sensor may additionally be used to maintain a predetermined distance between the parallel roller stabilization mechanism 900 and another parallel roller stabilization mechanism 900 on the frame 360. In at least one embodiment, there are two or more, three or more, or four or more parallel roller stabilization mechanisms 900 on a single frame 360.

[0128] The vertical motors 960 may be controlled independently of each other or in coordination with each of the four vertical motors 960 on a parallel roller stabilization mechanism 900. As mentioned, in some embodiments, the vertical motors 960 engage a single, stationary vertical belt 1010 routed along the frame to provide synchronized vertical motion. By driving along the vertical belt 1010 in unison, the vertical motors 960 ensure precise and stable elevation of the stabilizer gantry without introducing lateral misalignment or torsional stress. This design allows the stabilizer to maintain accurate positioning relative to the printed object while minimizing vibration during repositioning.

[0129] As mentioned above, during the additive manufacturing process, the printed object can be supported by multiple stabilizer gantries, such as by a parallel roller stabilization mechanism 900 and gripper mechanism 100, which are mounted to frame 360. At the start of printing, the build platform or plate 305 can be positioned above the vertical position of the stabilizer gantries along the z-axis. For example, one, two, or three stabilizer gantries can bepositioned in their lowest position (z-position) on the frame 360 and the build plate 305 can be positioned above the stabilizer gantries. This is advantageous so that the printhead 360 can move independently of the stabilizer gantries while always being vertically above the stabilizer gantries.

[0130] In embodiments with one stabilizer gantry, the build plate 305 can be provided at a position that is higher than the vertical height of the stabilizer gantry. Where there are two stabilizer gantries, the build plate 305 can be provided at a position that is higher than the vertical height of two stabilizer gantries. Where there are three stabilizer gantries, the build plate 305 can be provided at a position that is higher than the vertical height of three stabilizer gantries. The build plate 305 is generally fixed and static and its vertical height depends upon the number of stabilizer gantries on the frame 360. However, where stabilizer gantries can be readily removed, swapped, or added to the frame, the build plate 305 can be dynamically adjustable to ensure that the printing starts at a position above the lowest position of the stabilizer gantry or gantries (where the stabilizer gantries are stacked together at the lowest portion of the vertical axis of the frame 360).

[0131] As the printhead deposits successive layers, in some embodiments, the stabilizer gantries incrementally move upward to maintain structural support for the growing object. In some embodiments, the first stabilizer gantry engages the object only after the deposited material has sufficiently solidified, preferably at a point corresponding to approximately about 10-20 layers below the active printhead. In some embodiments, this ensures that the stabilizer does not interfere with unsolidified layers while providing early support to minimize deflection and vibration. After additional layers are printed, the first stabilizer can disengage from its initial contact point and can re-engage the object at a higher vertical level. Simultaneously, in some embodiments, a second stabilizer can engage the object at a lower level, maintaining continuous support. In some embodiments, two or three stabilizers operate in a coordinated sequence, moving upward along frame 360 in a manner analogous to the motion of a centipede’s legs. Similar to the motion of a centipede, at least one stabilizer maintains contact with the printed part while another stabilizer disengages and reengages at another vertical position in some embodiments. This sequential engagement and disengagement can reduce transient vibrations that result from the contact of the rollers on the part and / or adhesion forces from rubberized or foam contact surfaces, thereby improving thefidelity and resolution of the printed part. In some embodiments, only a single stabilizer gantry is provided, in which case the stabilizer slowly disengages the part and reengages the part at a new vertical position. But, additional support mechanisms may be provided in lieu of a second stabilizer gantry, such as printed stabilizers. Having a single stabilizer is advantageous because that, in some embodiments, can increase the height of the object that may be printed within the same frame 360 by lowering the height of the build plate 305 relative to the frame 360.

[0132] Maintaining the first stabilizer as close to the printhead as possible — without contacting unsolidified layers — is beneficial for optimal stability and print accuracy. Thus, a predetermined distance between the stabilizer and the frame may be calculated based upon the cure rate of the material in the printed part. In some embodiments, the distance between the highest stabilizer and the printhead is less than 30 layers or about 30 layers, less than 20 layers or about 20 layers, less than 10 layers or about 10 layers, less than 5 layers or about 5 layers, or any value, approximate value, or range of values in any of the foregoing ranges. Preferably, for solid plastics, in some embodiments, the first stabilizer is about 20 layers below the printhead, which allows the stabilizer to be as close to the print head as possible, or which allows the stabilizer to be adjacent to the printhead without causing deformation of unsolidified material.

[0133] Each of the stabilizers share the same vertical rails on the frame 360. Thus, the stabilizers and the printhead move independently of each other, but they do not pass one another along frame 360, necessitating the described “centipede-like” progression upward in the z-axis. This coordinated movement ensures uninterrupted support throughout the build process while reducing destabilizing forces that could compromise part quality.

[0134] The disclosed additive manufacturing apparatus may incorporate a motion control system comprising stepper motors and a programmable control interface, the control interface being typically provided on a personal computer. The system can utilize G-code scripts generated from slicing software or custom algorithms to define tool paths that govern both vertical (Z-axis) positioning and grip actuation of the stabilizing grippers.

[0135] As mentioned, each gripper assembly can be mounted on a movable horizontal frame (including transverse rails 930 and longitudinal rails 920, for example), the horizontal frame being actuated by stepper motors configured to respond to discrete pulse signals. These signals are derived from parsed G-code instructions, which specify positionalcoordinates, movement rates, and actuation sequences. The firmware may interpret commands such as G01, Z10, F100 to move the gripper vertically by 10 mm at a feed rate of 100 mm / min, or M280, P0, S90 to initiate grip closure via servo or stepper-driven linkage mechanisms. Alternatively, each gripper assembly can be mounted on a stationary horizontal frame member.

[0136] The control system may include homing routines and feedback loops using mechanical or pressure sensors embedded within the mechanism 900. In some embodiments, these sensors can detect contact with the printed object and trigger a controlled retraction followed by a slow re-engagement at approximately 5 mm / s to ensure precise stabilization without damaging the part.

[0137] In some embodiments, the parallel stage configuration employs dual stepper motors to achieve synchronized motion, enhancing stability during engagement with tall or slender printed structures. Alternatively, grippers are mounted on linear horizontal rails allowing movement along the Y-axis, and are actuated via a four-bar linkage or parallel stage mechanism,

[0138] In some embodiments, the G-code tool paths may be configured to be dynamically generated or modified based on the geometry of the object being printed, allowing adaptive positioning and actuation of the grippers. This integration of mechanical control and software scripting can, in some embodiments, enable precise, repeatable stabilization throughout the vertical build process.

[0139] Fig. 11 illustrates a cross-sectional view of an embodiment of a parallel roller stabilization mechanism 900 that can be included in any embodiments of the additive manufacturing systems disclosed herein. In this view, the transverse rail 930 is not cut away, whereas the longitudinal rail 920 is cut away. Rollers 910 are shown in an extended (unengaged position) as the transverse motors 940 are on the furthest distal point of the transverse rail 930. Transverse motors 940 and vertical motors 960 are shown.

[0140] Fig. 12 illustrates a side view of an embodiment of a parallel roller stabilization mechanism 900 that can be included in any embodiments of the additive manufacturing systems disclosed herein. Figure 11 is similar to Figure 10, but none of the objects are cut away. The view in Figure 11 is from the outside of the transverse side.

[0141] Fig. 13 illustrates a top plan view of an embodiment of a parallel roller stabilization mechanism 900 that can be included in any embodiments of the additivemanufacturing systems disclosed herein. Similar to Figures 9-11, the rollers 910 are shown in a disengaged position. After layers of the object have been printed, the rollers 910 can move into an engaged position to support one or more layers of the object as it is being printed.

[0142] Fig. 14 illustrates a front view of an embodiment of a parallel roller stabilization mechanism 900 according to some embodiments herein. Illustrated are longitudinal rail 920 and vertical motors 960.

[0143] Fig. 15 illustrates an example embodiment of a method for stabilizing an object during additive manufacturing. At step 1510, the method includes depositing one or more first layers from a printing head coupled to a frame onto one or more previously deposited layers or a build platform.

[0144] At step 1520, the method includes determining that the one or more first layers exceed a threshold height,

[0145] At step 1530, the method includes engaging a parallel roller stabilization mechanism 900 coupled to the frame at a first position to support the previously deposited one or more first layers.

[0146] At step 1540, the method includes depositing one or more second layers on top of the one or more first layers.

[0147] At step 1550, the method includes determining that the one or more second layers exceed a threshold height.

[0148] At step 1560, the method includes vertically adjusting the parallel roller stabilization mechanism 900 to support the one or more second layers at a vertical position higher than the first position.

[0149] The method 1500 may be repeated in subsequent printing steps so that the stabilization mechanism is moved upward as the height of the part dictates. Alternatively, at step 1460, one or more additional parallel roller stabilization mechanisms may be engaged in place of or in addition to the step of vertically adjusting the parallel roller stabilization mechanism. The one or more additional parallel roller stabilization mechanisms may be engaged to support the printed object below the first parallel roller stabilization mechanism.

[0150] Additional steps may be provided in any engaging step, for example at step 1530 or between steps 1530 and 1540. This may include determining that a threshold pressure, location coordinate, or distance from a printed object has been met, such as through a pressuresensor, proximity sensor, or open feedback loop. After achieving the pressure threshold or identifies that the rollers 910 are at a particular horizontal location, the parallel roller stabilization mechanism stops advancing the engagement with the printed object.

[0151] In some embodiments, the additive manufacturing mechanism applies a controlled or predetermined pressure to a three-dimensional (3D) printed object during printing or post-processing for stabilization. The pressure may be maintained within a threshold range of approximately 300 to 1,500 pascals (Pa), or sufficient to secure the object without inducing deformation or compromising dimensional accuracy. In some embodiments, the pressure threshold is about 300 Pa, about 400 Pa, about 500 Pa, about 600 Pa, about 700 Pa, about 1,000 Pa, about 1,500 Pa, or any number or range of numbers in between.

[0152] In some embodiments, the engagement of the stabilization mechanism is accomplished via actuated components equipped with load cells or equivalent force-sensing mechanisms, enabling real-time feedback and dynamic adjustment.

[0153] In some embodiments the parallel roller stabilization mechanism 900 or the gripper gantry 150 may be operated in an open loop system that does not require pressure or distance sensors. The open loop may reduce the complexity associated with supporting the object such that the engagement and support of the object can be based upon the print file (such as an STP file or other CAD file) and not sensor feedback. Engagement via an open-loop system allows support of the object with precision, such as movement in predetermined sub¬ millimeter increments.

[0154] In some embodiments, the open loop system moves parallel roller stabilization mechanism 900 or gripper gantry 150 to a vertical position (z position) on the frame 360 that needs to be stabilized. The part of the stabilizer that will engage the printed object (whether rollers 910 or gripper hands 110) are moved on both sides of the part in the x direction (i.e. transverse direction) to engage the part. The system calculates the outermost printed section (in the x direction) at that vertical layer and moves the rollers 910 or gripper hands 110 to that position. If the rollers 910 are moved to that position, the outermost portion of the rollers (the outermost radius of the rollers) is moved to the x direction such that it contacts the outermost portion of the printed part in the x direction. If the gripper hands 110 are moved to that position in the x direction, the gripper hands are moved such that the outermost portion of the gripper hands (whether a flat surface or the outermost portion of aparabolic gripper hand) contacts the outermost portion of the printed part in the x direction. In some embodiments the open loop system can be calibrated such that the outermost portion of the rollers 910 or the outermost portion of the gripper hands 110 can contact the outer surface of the printed part plus an additional predetermined distance, to exert pressure on the printed part. The predetermined distance is generally dependent upon the material that is being printed and the material on the roller or gripper hand. If the roller surface is made of foam, the distance could be on the order of millimeters, such as about 1, about 2, about 4, about 10, or about 20 millimeters or about 0.1% of the thickness, about 1% of the thickness, about 2% of the thickness, about 10% of the thickness, or about 20% of the thickness of the roller radius. If the roller surface is made of rubber, the predetermined distance is less than that of a foam surface in order to reduce pressure and adhesion to the printed part. In some embodiments, the additional contact or added pressure with the printed part in the x direction (the difference between the outermost section of the part and the edge of the stabilization surface) is less than about 5 mm, less than about 3 mm, less than about 1 mm, less than about 0.5 mm, less than about 0.1 mm or any value or range of values in between.

[0155] Where the printed object is symmetrical about a plane in the y-z direction, each longitudinal side (longitudinal rail 920) can be moved symmetrically to engage the part that is printed in the center of the frame. However, where the object is asymmetric or the part is not printed in the center of the frame, the longitudinal rails 920 can be moved individually to contact the part. The engagement of the part with the printed object can be calculated based upon the STP or other CAD file of the printed object. In some embodiments, calculating the outermost layer of the printed object includes calculating the 3D dimensional shape of the printed article, evaluating the outermost printed layer or layers at a particular z height, and determining the x-y coordinates for engagement of the stabilization rollers or hands in the x-axis. Where the part is asymmetric, the system calculates the stabilization coordinates for each side of the part for each of the longitudinal rails 920. The method could also include determining an offset for contact with the part based upon the surface material of the rollers, gripper hands, or planar contact surface. In some embodiments the system also includes moving each side of the longitudinal rails 920 to engage the printed part at the same time.

[0156] The contact surfaces of the grippers or rollers may include compliant materials such as rubber or foam to distribute force evenly and minimize localized stress. Apressure threshold ensures compatibility with a variety of thermoplastic and composite materials used in additive manufacturing, including but not limited to PLA, ABS, and PETG.

[0157] Depending upon the printed object, any of the mechanisms herein may use different actuation parts for stabilizing the printed object. For example, an end effector for a gripper mechanism can contain a roller, flat thin plate, or an edge wedge. In some embodiments, a linear contact between the roller or stabilizer and the part is preferred to stabilize the part and so that the stabilizer is better equipped to avoid overhangs or other features that may protrude in the x direction from the part. For example, where the stabilizer has a wedge-shaped cross-section, the longest linear side of the wedge contacts the point, not the pointed portion of the wedge. In some embodiments, minimizing the surface area of contact between the stabilizer and the part being printed can also reduce the risk of the stabilizer contacting an overhang or protrusion on the part, the contact with which can result in higher forces being applied to the part being printed and / or damage to the part being printed. In some embodiments, the end effector or the stabilization mechanism 900 can be changed midprinting, such as by disconnecting the stabilization mechanism 900 from the frame or gantry and re-attaching a different stabilization system to the frame or gantry.

[0158] Fig. 16 illustrates a perspective view of an embodiment of the stabilization and printing system having a parallel roller stabilization system according to some embodiments herein. A print head gantry 340 and two parallel roller stabilization mechanisms 900 are shown attached to the frame 360, but an additional parallel roller stabilization mechanism 900 could be provided in the frame 360 in other embodiments. The stationary vertical belt 1010 is depicted that provides the vertical movement mechanism for print head gantry 340 and two parallel roller stabilization mechanisms 900 in the illustrated embodiment. Build plate 305 is shown, which is provided at a height that exceeds the vertical distance of the tw’O parallel roller stabilization mechanisms 900 when they are in their lowest vertical configuration.

[0159] Fig. 17 illustrates a side view’ of the stabilization and printing system having a parallel roller stabilization system according to some embodiments herein. Similar to Figure 16, Figure 17 shows the print head gantry 340 and the two parallel roller stabilization mechanisms 900 attached to the frame 360.

[0160] Fig. 18 illustrates a top plan view of the stabilization and printing system having a parallel roller stabilization system according to some embodiments herein. The build plate 305 is provided in the center of the frame 360.

[0161] Fig. 19 illustrates a top plan view of an engaged parallel roller stabilization system 900 according to some embodiments herein. This view shows the two longitudinal rails 920 (or arms) in an engaged position, such as the position they would be in when they are engaging a printed part. Also shown are corresponding components that are depicted to Figure 9, which shows an unengaged parallel roller stabilization mechanism 900. As mentioned above, the transverse motors 940 driven on belts or rails on the transverse rails 930 can be moved in a symmetric fashion or an asymmetric fashion in order to engage a printed part.Additional Embodiments

[0162] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

[0163] Reference throughout the specification to “one example”, “another example”, “an example”, and so forth, means that a particular element (e.g., feature, structure, and / or characteristic) described in connection with the example is included in at least one example described herein, and may or may not be present in other examples. In addition, it is to be understood that the described elements for any example may be combined in any suitable manner in the various examples unless the context clearly dictates otherwise.

[0164] It is to be understood that the ranges provided herein include the stated range and any value or sub-range within the stated range, as if such value or sub-range were explicitly recited. For example, a range from about 2 nm to about 20 nm should be interpreted to include not only the explicitly recited limits of from about 2 nm to about 20 nm, but also to includeindividual values, such as about 3.5 nm, about 8 nm, about 18.2 nm, etc., and sub-ranges, such as from about 5 nm to about 10 nm, etc. Furthermore, when “approximately”, “about” and / or “substantially” are / is utilized to describe a value, this is meant to encompass minor variations (up to + / - 10%) from the stated value.

[0165] While several examples have been described in detail, it is to be understood that the disclosed examples may be modified. Therefore, the foregoing description is to be considered non-limiting.

[0166] While certain examples have been described, these examples have been presented by way of example only and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure,

[0167] Features, materials, characteristics, or groups described in conjunction with a particular aspect, or example are to be understood to be applicable to any other aspect or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The protection is not restricted to the details of any foregoing examples. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0168] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, beexcised from the combination, and the combination may be claimed as a sub-combination or variation of a sub-combination.

[0169] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results, unless provided otherwise herein. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some examples, the actual steps taken in the processes illustrated and / or disclosed may differ from those shown in the figures. Depending on the example, certain of the steps described above may be removed or others may be added. Furthermore, the features and attributes of the specific examples disclosed above may be combined in different ways to form additional examples, all of which fall within the scope of the present disclosure.

[0170] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular example. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0171] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain examples include, while other examples do not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more examples.

[0172] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain examples require the presence of at least one of X, at least one of Y, and at least one of Z.

[0173] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, for numerical values, the terms “approximately” and “about” are meant to describe a range within or equal to 10% of the stated value.

[0174] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred examples in this section or elsewhere in this specification and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.

[0175] Although the foregoing invention has been described in terms of certain preferred embodiments, other embodiments will be apparent to those of ordinary' skill in the art. Additionally, other combinations, omissions, substitutions, and modifications will be apparent to the skilled artisan, in view of the disclosure herein. Accordingly, the present invention is not intended to be limited by the recitation of the preferred embodiments but is instead to be defined by reference to the appended claims.

[0176] The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive manner and unless otherwise indicated refers to the ordinary meaning as would be understood by one of ordinary skill in the art in view of the specification. Furthermore, embodiments may comprise, consist of, consist essentially of, several novel features, no single one of which is solely responsible for its desirable attributes or is believed to be essential to practicing the embodiments herein described. As used herein, the section headings are for organizational purposes only and are not to be construed as limiting the described subject matter in any way. When definitions of terms in incorporated references appear to differ from the definitions provided in the present teachings, the definition provided in the present teachings shall control. It will be appreciated that there is an implied “about” prior to the temperatures, concentrations, times, etc. discussed in the present teachings, such that slight and insubstantial deviations are within the scope of the present teachings herein unless provided otherwise herein.

[0177] Although this disclosure is in the context of certain embodiments and examples, those of ordinary skill in the art will understand that the present disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses of the embodiments and obvious modifications and equivalents thereof In addition, while several variations of the embodiments have been shown and described in detail, other modifications, which are within the scope of this disclosure, will be readily apparent to those of ordinary skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to form varying modes or embodiments of the disclosure. Thus, it is intended that the scope of the present disclosure herein disclosed should not be limited by the particular disclosed embodiments described above.

Claims

WHAT IS CLAIMED IS:

1. An additive manufacturing apparatus comprising:a build plate:a frame with vertical and horizontal dimensions;a print head configured to dispense build material;a print head gantry coupled to vertical columns of the frame and configured to support and automatically move the print head relative to the frame, wherein the print head gantry has one or more motors, each motor coupled to a stationary belt for movement in the vertical direction; andone or more stabilizers attached to the frame and configured to move independently of the print head gantry, the one or more stabilizers each comprising:arms for engaging, disengaging, and supporting a printed object; one or more motors for movement in the vertical direction, each motor coupled to one of the stationary belts;wherein the one or more stabilizers and the print head gantry are coupled to the same stationary belts.

2. The apparatus of Claim 1, wherein at least two stabilizers are coupled to the frame and are configured to move relative to each other in a vertical direction, wherein the motors of the at least two stabilizers are coupled to the same stationary belts that the print head gantry is coupled to.

3. The apparatus of Claim 1, wherein the one or more stabilizers have one or more rollers for engaging and supporting the printed object.

4. The apparatus of Claim 1, wherein the print head gantry’ has four corners with motors in each corner, the one or more stabilizers have four corners with motors in each corner, and the frame has four vertical columns with a stationary belt in each vertical column; wherein each corner of the print head gantry’ and one or more stabilizers is attached to one of the four stationary belts..

5. The apparatus of Claim 4, wherein the frame has a vertical dimension at least twice that of the frame’s horizontal dimension.

6. The apparatus of Claim 1, wherein a portion of the stabilizer that touches and supports the printed object is composed of rubber or foam.

7. The apparatus of Claim 1, wherein the print head gantry' and the one or more stabilizers connect to the frame via one or more linear bearings.

8. The apparatus of Claim 1, wherein the one or more stabilizers each have one or more transverse motors for movement of the stabilizer arms, wherein the transverse motors are coupled to one or more stationary belts.

9. The apparatus of Claim 1, wherein the build plate is stationary.

10. The apparatus of Claim 1, wherein the stabilizers do not have any pressure or proximity sensors.

11. An additive manufacturing apparatus comprising:a stationary build plate;a frame with vertical and horizontal dimensions;a print head coupled to the frame configured to automatically move relative to the frame by means of a print head gantry; andat least one parallel stage mechanism attached to the frame for stabilizing a printed object, wherein the parallel stage mechanism comprises:one or more rollers coupled to longitudinal sides of the parallel stage mechanism; andat least two motors for independently moving the longitudinal sides of the parallel stage mechanism in a horizontal direction toward and away from each other;at least two motors for moving the parallel stage mechanism on the frame in the vertical dimension;wherein the parallel stage mechanism is configured to move independently of the print head along the length of the vertical dimension.

12. The apparatus of Claim 11, wherein the frame has a vertical height at least 150% of the frame’s width or depth.

13. A method for stabilizing an object during additive manufacturing, the method comprising:depositing one or more first layers onto a stationary build platform from a printing head coupled to a frame;determining that the one or more first layers exceed a threshold height; engaging a first or a second stabilizer to support at least a portion of the one or more first layers;depositing one or more second layers on top of the one or more first layers; determining that the one or more second layers exceed a threshold height; and moving the remaining first or second stabilizer to support at least a portion of the one or more second layers;wherein the first stabilizer is vertically higher than the second stabilizer.

14. The method of Claim 13, wherein the first and second stabilizers engage the printed object with two or more rollers.

15. The method of Claim 13, additionally comprising determining a threshold pressure for supporting the object via a pressure sensor on the first or the second stabilizer.

16. The method of Claim 13, additionally comprising determining the location of the widest dimension of the object at a vertical heigh and advancing a side of the stabilizer to support the material at that location.

17. The method of Claim 13, wherein the first stabilizer and the second stabilizer are configured to support a printed object with a vertical to horizontal dimension of at least18. A method for stabilizing multiple levels of a printed object, the method comprising:depositing first layers;moving a first stabilizer vertically to a first region that is vertically beneath the first layers;actuating the first stabilizer to support the first region with one or more rollers; depositing second layers on top of the first layers;disengaging the first stabilizer and moving the first stabilizer vertically in a disengaged position such that the first stabilizer does not roll along the part;reengaging the first stabilizer at second position that is vertically higher than the first position.

19. The method of Claim 18, wherein the first stabilizer comprises a parallel stage mechanism with longitudinal and transverse sides, rollers coupled to longitudinal sides of the parallel stage mechanism, and at least two motors for moving the longitudinal sides of the parallel stage mechanism in a horizontal direction toward and away from each other.

20. The method of Claim 18, wherein the first stabilizer is a roller stabilizer, and the method additionally comprises actuating a second roller stabilizer in a third region that is vertically beneath the first stabilizer.

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