SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER
A three-dimensional (3D) printer device includes an extruder configured to deposit a material on a deposition platform, an actuator coupled to at least one of the extruder or the deposition platform, and a controller coupled to the actuator. The controller is configured to cause the extruder to deposit a first portion of the material corresponding to a first line, and after depositing a second portion of the material corresponding to a first end of the first line, to cause relative motion of the extruder and the deposition platform such that the extruder moves back along the first line while the extruder concurrently moves away from the deposition platform.
This application claims the benefit of U.S. Provisional Patent Application No. 62/208,222, filed Aug. 21, 2015 and entitled “Closed-Loop 3D Printing Incorporating Sensor Feedback,” U.S. Provisional Patent Application No. 62/340,389, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER,” U.S. Provisional Patent Application No. 62/340,421, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER,” U.S. Provisional Patent Application No. 62/340,453, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTING DEVICE,” U.S. Provisional Patent Application No. 62/340,436, filed May 23, 2016 and entitled “SYSTEM AND METHOD TO CONTROL A THREE-DIMENSIONAL (3D) PRINTER,” and U.S. Provisional Patent Application No. 62/340,432, filed May 23, 2016 and entitled “3D PRINTER CALIBRATION AND CONTROL;” the contents of each of the aforementioned applications are expressly incorporated herein by reference in their entirety.
FIELD OF THE DISCLOSUREThe present disclosure is generally related to control of a three-dimensional (3D) printer device.
BACKGROUNDImprovements in computing technologies and material processing technologies have led to an increased interest in computer-driven additive manufacturing techniques, such as three-dimensional (3D) printing. Generally, 3D printing is performed using a 3D printer device that includes an extruder, one or more actuators, and a controller coupled to some form of structural alignment system, such as a frame. The controller is configured to control the extruder and the actuators to deposit material, such as a polymer-based material, in a controlled arrangement to form a physical object.
SUMMARYIn a particular implementation, a method includes obtaining model data representing a three-dimensional (3D) model of an object. The method also includes processing the model data to generate a set of commands to direct a 3D printer device to extrude a material to form a physical model associated with the object. The set of commands includes one or more first commands to cause relative motion of an extruder of the 3D printer device and a deposition platform of the 3D printer device during deposition a first portion of the material to form a portion of a first line, and after depositing a second portion of the material corresponding to a first end of the first line, to cause relative motion of the extruder and the deposition platform such that the extruder moves back along the first line while the extruder concurrently moves away from the deposition platform.
In another particular implementation, a method includes obtaining model data representing a three-dimensional (3D) model of an object. The method also includes processing the model data to generate a set of commands to direct a 3D printer device to extrude a material to form a physical model associated with the object. The set of commands includes one or more first commands to cause relative motion of an extruder of the 3D printer device and a deposition platform of the 3D printer device during deposition of a portion of the material corresponding to a line. The set of commands further includes one or more second commands to adjust an extrusion rate of the extruder based on an acceleration rate of the relative motion.
In a particular implementation, a three-dimensional (3D) printer device includes an extruder configured to deposit a material on a deposition platform, an actuator coupled to at least one of the extruder or the deposition platform, and a controller coupled to the actuator. The controller is configured to cause the extruder to deposit a first portion of the material corresponding to a first line, and after depositing a second portion of the material corresponding to a first end of the first line, to cause relative motion of the extruder and the deposition platform such that the extruder moves back along the first line while the extruder concurrently moves away from the deposition platform.
In another particular implementation, a three-dimensional (3D) printer device includes an extruder configured to deposit a material on a deposition platform, an actuator coupled to at least one of the extruder or the deposition platform, and a controller coupled to the actuator. The controller is configured to cause the actuator to cause relative motion of the extruder and the deposition platform during deposition of a portion of the material corresponding to a line and to adjust a flow rate of the extruder based on an acceleration rate of the relative motion.
In another particular implementation, a method includes moving an extruder of a three-dimensional (3D) printer device relative to a deposition platform of the 3D printer device during deposition a material to form a portion of a first line. The method also includes, after depositing a portion of the material corresponding to a first end of the first line, moving the extruder back along the first line and concurrently moving the extruder away from the deposition platform.
In another particular implementation, a method includes during extrusion of a material by an extruder of a three-dimensional (3D) printer device, moving the extruder relative to a deposition platform of the 3D printer device. The method also includes, during movement of the extruder, adjusting an extrusion rate of the extruder based on an acceleration rate of relative motion of the extruder and the deposition platform.
The features, functions, and advantages that have been described can be achieved independently in various implementations or may be combined in yet other implementations, further details of which are disclosed with reference to the following description and drawings.
A 3D printer may be a peripheral device that includes an interface to a computing device. For example, the computing device may be used to generate or access a 3D model of an object. In this example, a computer-aided design (CAD) program may be used to generate the 3D model. A slicer application may be to process the 3D model to generate commands that are executable by the 3D printer to form a physical model of the object. For example, the slicer application may generate G-code (or other machine instructions) that instruct the controller of the 3D printer when and where to move the extruder and provides information regarding 3D printer settings, such as extruder temperature, material feed rate, extruder movement direction, extruder movement speed, among others.
The slicer application may generate the G-code or machine instructions by dividing the 3D model into layers (also referred to as “slices”). The slicer application determines a pattern of material to be deposited to form a physical model of each slice. Generally, the physical model of each slice is formed as a series or set of lines of extruded material. The G-code (or other machine instructions), when executed by the controller of the 3D printer, cause the extruder to deposit a set of lines of the material in a pattern to form each layer, and one layer is stacked upon another to form the physical model. Layer stacking arrangements or support members can also be used to form lines of the material that are partially unsupported (e.g., arches).
There are many ways that the slicer application can arrange the pattern of materials to be deposited to form each layer. Characteristics of a 3D print job may vary depending on how the slicer application arranges the pattern lines that make up each of the layers. For example, two different patterns of lines may have different printing characteristics, such as an amount of time used to print the physical model, an amount of material used to print the physical model, etc. As another example, two different patterns of lines may result in physical models that have different characteristics, such as interlayer adhesion, weight, durability, etc. Accordingly, different slicer applications or different settings or configurations of the slicer application can affect the outcome of a particular 3D print job.
Besides the arrangement of the pattern of materials, other factors can also affect print quality. For example, during extrusion, some materials have a tendency to clog or partially clog a nozzle of the extruder. As the nozzle begins to clog, the flow properties of the nozzle change. To illustrate, a decreased flow area of the nozzle can lead to forming lines that have decreased cross-sectional area, which can reduce print quality. Additionally, if a clog breaks loose during extrusion, the clog can be deposited as a clump or other line deformity. As another example, some materials may aggregate around the nozzle during extrusion to forms clumps that do not occlude the nozzle but can nevertheless lead to problems. These clumps of material can break loose during extrusion to cause clumps or other line deformities in the deposited material.
Accordingly, one method of improving print quality is to periodically or occasionally interrupt the extrusion process to clean the extruder. The extruder can be cleaned by moving the extruder to a cleaning station that includes one or more brushes or scrapers. The brushes or scrapers may be passive such that the extruder is moved across the brushes or scrapers to remove excess material. Alternately, the brushes or scrapers may be active (e.g., moving linearly or rotating) to contact the extruder to remove excess material. The cleaning station may also include a waste catcher to catch and retain the removed excess material away from the object being printed. The waste catcher may also be used to purge material from the extruder. For example, material may be purged from the extruder when changing from using a first material to using a second material. As another example, if the material being deposited is reactive (e.g., cures after being mixed or upon exposure to air) some or all of the material may be purged when the extruder is cleaned to avoid curing of the material in the extruder.
Different types of extruders may be used to deposit different types of materials (e.g., physically or chemically distinct materials). For example, a filament-fed extruder may be used to deposit thermoplastic polymers, such as polylactic acid (PLA), acrylonitrile butadiene styrene (ABS) polymers, and polyamide, among others. Paste extruders, such as pneumatic or syringe extruders, may be used to deposit materials that are flowable at room temperature (or at a temperature controlled by the 3D printer). Examples of materials that may be deposited using paste extruders include silicone polymers, polyurethane, epoxy polymers. Paste extruders may be especially useful to deposit materials that undergo curing upon exposure to air or when mixed together (such as multi-component epoxies).
Some 3D printers include multiple extruders to improve print speed or to enable printing with multiple different materials. For example, a first extruder may be used to deposit a first material, and a second extruder may be used to deposit second material. In this example, the first and second materials may have different visual, physical, electrical, chemical, mechanical, and/or other properties. To illustrate, the first material may have a first color, and the second material may have a second color. As another illustrative example, the first material may have first chemical characteristics (e.g., may be a thermoplastic polymer), and the second material may have a second chemical characteristics (e.g., may be a thermoset polymer). As yet another illustrative example, the first material may be substantially non-conductive, and the second material may be conductive. In this example, the first material may be used to form a structure or matrix, and the second material may be used to form conductive lines or electrical components (e.g., capacitors, resistors, inductors) of a circuit.
When a 3D printer uses multiple extruders to deposit multiple materials, one extruder may be idle (i.e., not extruding material) while another is depositing material. For example, while a first extruder is depositing a matrix material, a second extruder may be idle. Idle extruders may be particularly subject to clogging since flow of material through the extruder may reduce clogging. If the idle extruder becomes clogged, it can lead to reduced print quality as a result of clumps in material that is later deposited by the extruder.
Accordingly, to improve print quality, a print job may be periodically or occasionally interrupted to clean or purge an idle extruder. To illustrate, after a first extruder deposits a first portion of a first material to form part of a physical object, a second extruder (that was idle while the first extruder deposited the first portion of the first material) may be cleaned. Subsequently, the print job may be resumed. For example, the first extruder may deposit a second portion of the first material to form another part of a physical object. Alternately, the second extruder may deposit a second material, or a third extruder may deposit a third material.
In some implementations, the first extruder may also be cleaned while the print job is interrupted. For example, cleaning of the first extruder and of the second extruder may be scheduled so that both are cleaned when either one is to be cleaned.
In some implementations, cleaning operations may be encoded in the G-code or other machine instructions. For example, the slicer application may schedule cleaning operations for one extruder or for multiple extruders. In this example, the G-code or other machine instructions include a sequence of operations associated with printing the physical model (e.g., extrusion operations, extruder movement operations, etc.) and at least one cleaning operation is embedded with the sequence of operations associated with printing the physical model.
In other implementations, cleaning operations may be scheduled or implemented by the controller of the 3D printer. For example, the slicer application may provide G-code or other machine instructions that specify a sequence of operations associated with printing the physical model, and, during printing, the controller may interrupt execution of the sequence of operations to perform cleaning operations.
The cleaning operations may be performed based on an amount of material deposited. For example, the slicer application may determine a quantity of material that will be used to form a portion of the physical model, and the slicer application may insert a cleaning operation into the G-code or machine instructions when the quantity of material that will be used to form the portion satisfies a threshold. Alternately, the controller of the 3D printer may track the quantity of material that has been deposited and interrupt the printer to clean one or more extruders when the quantity of material that has been deposited satisfies a threshold. In other implementations, deposition time of an extruder, idle time of an extruder, or both may be determined or tracked to schedule cleaning operations.
Some materials begin curing (i.e., solidifying) upon exposure to air or upon mixing. For example, two-part epoxies include an epoxy resin and a hardening agent. After the epoxy resin and the hardening agent are mixed, the mixture begins to cure. When a 3D printer uses such materials, one or more extruders of the 3D printer may be cleaned or purged based on a time since mixing the materials (or a time since the materials were exposed to air). For example, if a material that cures after mixing is to be used, the slicer application may generate G-code (or other machine instructions) for mixing the materials. In this example, the slicer application may cause the materials to be mixed based on when the mixture will be needed during printing of the physical model. Additionally, the slicer application may track (e.g., by summing deposition time of all extruders of the 3D printer) when to schedule a cleaning operation or a purging operation to prevent the mixture from curing in the extruder. In another example, the G-code (or other machine instructions) include instructions for mixing the materials, and the controller of the 3D printer determines (e.g., based on a timer) when to schedule a cleaning operation or a purging operation to prevent the mixture from curing in the extruder.
The arrangement of the pattern of materials to be deposited to form each layer may be of particular concern for certain materials. For example, certain materials have a tendency to form blobs or other irregularly shaped deposits (sometimes referred to as “kisses”) at the start of a line, the end of a line, or both. A kiss can cause an issue with layer stacking if a portion of the kiss extends above the layer on which it is deposited. A kiss can also, or in the alternative, cause an issue with line arrangement with the layer being printed if the kiss extends beyond the width of its line into an area associated with another line.
Slicing the 3D model in a manner that reduces line starts and stops can reduce the number of kisses in a physical model. The number of line starts and stops can be reduced by configuring the slicer application to use as few lines as possible (or as few lines as practical in view of other settings or goals) for each layer. For example, when a line extends to an edge of the layer, rather than ending the line, lifting the extruder head and moving to a new location for the next line, the slicer application may instruct the 3D printer to turn the line (e.g., in a U-turn) to continue the line in another direction.
The number of line starts and stops can also be reduced by extending lines between layers. For example, when a first layer is complete, rather than ending the line and lifting the extruder head to begin printing the next layer, the line may be extended to overlay a portion of the first layer to immediately begin printing a portion of the second layer. To illustrate, if the first layer is in a horizontal plane, the material forming the line may be deposited to form a vertical or oblique riser up to a plane of the second layer.
As another example, a first portion of a physical model may be formed by stacking multiple layers of material (e.g., a base layer and one or more additional layers at least partially overlaying the base layer) before moving the extruder head to a different location to form another portion of the base layer. In this example, the multiple layers may be stacked using a single continuous deposition step (e.g., with one start and one stop).
Another method that may be used to reduce kisses is to perform additional steps at the end of a line. For example, when a line ends, rather than ceasing extruder flow and lifting the extruder head, the extruder head may be caused to move backward (e.g., in a direction back along the line that was just deposited) as the extruder flow is stopped, as the extruder head is lifted, or both. Alternately, the extruder flow can be ceased before the line end is reached. After the extruder reaches the line end, the extruder head can be lifted and moved back along the line. By causing the extruder head to backtrack along the line with flow stopped or as flow stops, potential kiss at the line end can be smoothed out.
Yet another method that may be used to reduce kisses is to control extruder flow in a manner that accounts for acceleration of the extruder head. For example, pressure applied to the material being deposited, temperature of the material, filament feed rate, or a combination thereof, may be used to control a flow rate of material from the extruder. The G-code (or other machine instructions) may include settings for the temperature, the pressure, the filament feed rate, or a combination thereof. Additionally, the G-code (or other machine instructions) may include information indicating a velocity (e.g., speed and direction of travel) for movement of the extruder head during deposition. At the beginning of a line, the extruder head is not able to instantaneously achieve the indicated velocity. Rather, due to inertia and/or settings of the 3D printer, the extruder head velocity gradually increases to the indicated velocity. During this acceleration from a starting velocity to the indicated velocity, if the same extruder flow rate is used as is used when the extruder is at the indicated velocity, more material will be deposited at the beginning of the line than in the remainder of the line. A similar issue arises at the end of the line. That is, when the extruder approaches the end of a line, the extruder is not able to decelerate from the indicated velocity to an ending velocity (e.g., stopped) instantaneously. Rather, the extruder head velocity gradually decreases to the ending velocity. During this deceleration (i.e., negative acceleration), if the same extruder flow rate is used as is used when the extruder is at the indicated velocity, more material will be deposited at the end of the line than in the remainder of the line. Accordingly, kisses or other line irregularities can be reduced by controlling the flow rate of the extruder based on an acceleration rate of the extruder.
In a particular embodiment, the computing device 102 includes a processor 103 and a memory 104. The computing device 102 may include a 3D modeling application 106. The 3D modeling application 106 may enable generation of 3D models, which can be used to generate model data 107 descriptive of the 3D models. For example, the 3D modeling application 106 may include a computer-aided design application.
The computing device 102 or the 3D printer device 101 includes a slicer application 108. The slicer application 108 may be configured to process the model data 107 to generate commands 109 that the 3D printer device 101 (or portions thereof) uses during generation of a physical model of an object represented by the model data 107. In the particular embodiment illustrated in
The 3D printer device 101 includes a frame 110 and support members 111 arranged to support various components at the 3D printer device 101. In particular embodiments, the 3D printer device 101 may include a deposition platform 112. In other embodiments, the 3D printer device 101 does not include a deposition platform 112 and another substrate or surface may be used for deposition. The 3D printer device 101 also includes one or more printheads. For example, in the embodiment illustrated in
Each printhead 113-115 is coupled to receive a material that may be deposited to form a portion of a physical model of an object. For example, the first printhead 113 may be coupled to a first material container 119 that includes a first material 120. As another example, the second printhead 114 may be coupled to a second material container 121 that includes a second material 122. The Nth printhead 115 may be coupled to a mixer 127. The mixer 127 may be coupled to a first component container 123 and a second component container 125. The first component container 123 may be configured to retain a first component 124, such as a resin. In this example, the second container 125 may be configured to contain a second component 126, such as a hardening agent. In the example illustrated in
Proportions of the components 124, 126 supplied to the mixer 127 may be controlled by a controller 141 of the 3D printer device 101. The controller 141 may also, or in the alternative, control one or more actuators 143 to move the deposition platform 112 relative to the printheads 113-115, to move the printheads 113-115 relative to the deposition platform 112, or both. For example, in a particular configuration, the deposition platform 112 may be configured to move in a Z direction 140. In this example, the printheads 113-115 may be configured to move in an X direction 138 and a Y direction 139 relative to the deposition platform 112. Thus, movement of one or more printheads 113-115 relative to the deposition platform 112 may involve movement of the deposition platform 112, movement of one or more of the printheads 113-115, or movement of both the deposition platform 112 and the printheads 113-115. In other examples, the deposition platform 112 may be stationary and one or more of the printheads 113-115 may be moved. In yet other examples, the one or more printheads 113-115 may be stationary and the deposition platform 112 may be moved.
The 3D printer device 101 of
The purging station 137 may be configured to receive a material from one or more of the printheads 113-115 in order to purge an extruder of the printhead 113-115. For example, the mixture 128 may begin to cure upon mixing. Accordingly, the mixture 128, or a portion thereof, may be purged occasionally to avoid curing of the mixture 128 within the extruder 134 or within the mixer 127. As an example, when the Nth extruder 134 is purged, the Nth printhead 115 may be moved adjacent to or over the purge station 137, and at least a portion of the mixture 128 may be extruded by the extruder 134 into the purge station 137. The purge station 137 may be configured to be removable or replaceable such that after the mixture 128 cures in the purge station 137, the cured mixture 128 can be removed without damaging components of the 3D printer device 101. Other materials used by other extruders may be deposited in the purge station 137 occasionally. For example, the second material 122 may include a paste that begins to cure upon exposure to air. In this example, the second extruder 132 may be purged at the purge station 137 occasionally to avoid clogging the second extruder tip 133, the second extruder 132, or both. Further, the first material 120 may include a filament or other thermoplastic polymer, and the first material 120 may be occasionally purged at the purge station 137 in order to retain desirable properties of the filament, to avoid clogging the extruder 130, or both. When a printhead 113-115 is purged at the purge station 137, the printhead 113-115 may also be cleaned at the cleaning station 136 to prepare the printhead 113-115 for use.
The 3D printer device 101 may also include a memory 142 accessible to the controller 141. The controller 141 may include or have access to one or more timers 144, one or more material counters 145, or both. The material counters 145 may track a quantity of materials in the material containers 119, 121, 123, 125, a quantity of material in the mixer 127, a quantity of each material deposited to form a physical model of an object, etc. For example, during formation of a first physical model (or a portion of the first physical model), the first material 120 may be deposited by the first printhead 113. During formation of the first physical model, the material counter 145 may track a quantity of the first material 120 that has been deposited. The material counter 145 may also, or in the alternative, track a quantity of material remaining. To illustrate, during formation of the first physical model, while the first material 120 is being deposited, the material counter 145 may track a quantity of the first material 120 that remains in the first material container 119. As another example, when the mixture 128 is deposited to form a portion of the physical model, the material counter 145 may track a quantity of the mixture 128 remaining in the mixer 127. When the quantity of material remaining in the mixer 127 is below a threshold, the controller 141 may cause the mixture 128 to be purged at the purge station 137 and may cause the first component container 123 and the second component container 125 to provide the first component 124 and the second component 126, respectively, to the mixer 127 to generate a new mixture 128. Alternatively, portions of the first component 124 and the second component 126 may be added to an existing mixture 128 in the mixer 127.
The timers 144 may track an amount of time associated with particular activities of the 3D printer device 101. For example, a first timer of the timers 144 may track a time since mixing the mixture 128. The time since mixing the mixture 128 may be used to determine when to purge the mixture 128. For example, the mixture 128 may be purged before a cure time associated with the mixture 128 is reached. The timers 144 may also, or in the alternatively, track how long a particular printhead 113-115 has been idle. For example, during deposition of the first material 120 to form a portion of a physical model, the second material 122 may sit idle in the second printhead 114 or in the second material container 121. Since the second material 122 may begin to cure upon exposure to air, the portion of the second material 122 exposed at the second extruder tip 133 may begin to cure, potentially causing a clog. Accordingly, based on the timers 144 indicating that the second printhead 114 has been sitting idle for a threshold amount of time, a print activity being performed by the 3D printer device 101 may be interrupted to move the second printhead 114 to the cleaning station 136, the purging station 137, or both, to remove a portion of the second material 122 from the second extruder 132 to avoid clogging the second extruder 132.
As another example, the timers 144 may indicate how long a particular extruder has been in use. For example, when the first extruder 130 is being used to deposit a portion of material corresponding to a physical object, the first extruder 130 may be cleaned periodically to remove excess material that occasionally aggregates around the first extruder tip 131. Thus, based upon the timers 144, a 3D printing operation being performed by the 3D printer device 101 may be interrupted, and the first extruder 130 may be moved to the cleaning station 136, to the purging station 137, or both, to clean the first extruder tip 131.
After cleaning of a particular extruder has been performed, the 3D printing operations may resume where they left off. For example, when the first extruder 130 was being used to form a portion of a physical model, and the timer 144 or the material counter 145 indicated cleaning was needed, the print activity may be interrupted, the first extruder 130 may be cleaned, purged or both, and then the printing activity may resume with the first extruder 130 depositing the first material to form a second portion of the physical object. Alternatively, cleaning operations may be scheduled based on the timers 144, the material counter 145, or both, such that the cleaning and/or purging operations occurs between uses of particular extruders. For example, while the first extruder 130 is in use to form a first portion of a physical model, the timers 144, the material counters 145, or both, may reach a value indicating that cleaning is needed. After the first operations being performed by the first extruder 130 is complete (e.g., when an end point associated with the first extruder 130 is reached), the cleaning operation may be performed. The cleaning operation may include cleaning and/or purging the first extruder 130, the second extruder 132, the Nth extruder, or a combination thereof. After the cleaning operation has been performed, printing operations may resume, for example, with the second extruder depositing the second material 122 to form a second portion of the 3D model of the physical object.
In a particular embodiment, the memory 142 includes cleaning and purging control instructions 147. The cleaning and purging control instructions 147 may include instructions (e.g., a cleaning sequence of instructions, a purging sequence of instructions, or both) that facilitate cleaning and purging of the printheads 113-115. For example, when the controller 141 determines that a cleaning operation is to be performed, the controller 141 may interrupt operations being performed at the 3D printer device 101 and execute the cleaning sequence of instructions of the cleaning and purging control instructions 147. As another example, when the controller 141 determines that a purging operation is to be performed, the controller 141 may interrupt operations being performed at the 3D printer device 101 and execute the purging sequence of instructions of the cleaning and purging control instructions 147.
In some implementations, the cleaning and purging control instructions 147 may include thresholds associated with the timers 144, thresholds associated with the material counters 145, or both. To illustrate, the thresholds may include a cure time associated with the mixture 128 or a threshold time that precedes the cure time at which the mixture 128 is to be purged and/or cleaned. As another example, the thresholds may include a downtime limit associated with one or more of the printheads 113-115. The downtime limit may be used to determine whether one or more of the printheads 113-115 should be cleaned based on a downtime of the particular printhead. As another example, the thresholds may include use time thresholds associated with the particular printhead 113-115. The use time thresholds may indicate how long a particular printhead 113-115 can be in use before cleaning and/or purging of the particular printhead 113-115 is needed. As another example, the thresholds may include material quantity thresholds that indicate how much material a particular printhead 113-115 can deposit before cleaning and/or purging of the particular printhead 113-115 is needed. In some implementations, the thresholds may be stored as part of the settings 150.
The cleaning and purging control instructions 147 may also include instructions that cause more than one printhead to be cleaned at a time. For example, when the timers 144 or the material counters 145 indicates that the first printhead 113 is to be cleaned, the cleaning and control instructions 147 may also cause the second printhead 114, the Nth printhead 115, or both, to be cleaned, so that multiple cleaning operations are performed concurrently or sequentially to reduce interruption to print operations.
The memory 142 may also include calibration data 148. The calibration data 148 may include information that indicates relative positions of the printheads 113-115. In the particular example illustrated in
The memory 142 may also include test print data 151. The test print data 151 may be used to generate at least a portion of the calibration data 148. For example, the test print data 151 may include commands to generate one or more test print objects using multiple of the printheads 113-115. Positions, orientations, and other information about the test print objects may be measured after a test print is performed and the measurements may be used to adjust the calibration data 148. For example, the 3D printer device 101 may include a measurement device, such as a scanning device (not shown), that automatically measures the test print objects. Alternately, the test print objects may be manually measured and updated calibration data may be provided via a user interface (not shown) or via the computing device 102.
The memory 142 may also include end-of-line-technique instructions 149. The end-of-line-technique instructions 149 include instructions that enable formation of line ends having a target width without undesired characteristics, such as bulges and blobs. Examples of end-of-line techniques are described further with reference to
Accordingly, the 3D printer device 101 enables use of multiple printheads 113-115 with multiple distinct materials, such as the first material 120, the second material 122, the mixture 128, or a combination thereof, to form physical models of 3D objects corresponding to model data 107. The 3D printer device 101 is able to improve printing outcomes by controlling cleaning and purging of the printheads 113-115 and by using improved end-of-line techniques.
In
In the example illustrated in
As a result of the initial gap, a larger quantity of material is deposited at the beginning of the line 304 than at other portions of the line 304, resulting in a blob 306 at the beginning of the line 304. The blob 306 has a blob width 310 that is significantly wider than a target line width 308 of the line 304. The blob 306 results from a difference between the amount of time for the extruder to reach a desired velocity (e.g., an acceleration rate of the extruder) and the amount of time for the extrusion rate to reach a desired extrusion rate. For example, when the extruder is a pasted extruder, pressure applied to a plunger of the extruder results in virtually immediate extrusion at the desired rate. In contrast, inertia and mechanical limitations limit a rate at which the extruder can accelerate.
A line 324 formed using the end-of-line technique illustrated by the graph 320 is also illustrated in
After obtaining the 3D model 400 or the model data 107, a slicer application, such as the slicer application 108, may perform slicing operations to generate the commands 109. In the example illustrated in
After the sliced model 402 is generated, the slicer application 108 may modify one or more of the slices based on characteristics of the 3D printer device to be used to print the physical model of the 3D model 400. For example, the slicer application 108 may access the settings 150, the calibration data 148, or both, associated with the 3D printer device 101 of
In the example illustrated in
For example, the slicer application may be configured to generate commands that favor printing one material at a time, and then print with a different material. To illustrate, a first material may be used to form multiple layers corresponding to a set of slices. Even when the slices include regions corresponding to a second material, the slicer application may arrange the commands so that all of the regions that use the first material are printed first. Subsequently, regions that use the second material may be printed, such as by printing on a non-planar surface formed by the first material or by injecting the second material into tunnels or voids defined in the first material. When the first material encloses the second material, the first material may be deposited until just before the access to a region that is ton include the second material is closed off, then the second material may be deposited, as illustrated in
As illustrated in
Modifying the slices results in a modified sliced model 410, which may be further processed. For example, when a slice, such as the slice 414, includes an enclosed void region 418, the slicer application may process that slice 414 as multiple separate or coupled polygons to limit or reduce starting and stopping a deposition process. During formation of a physical model corresponding to the 3D model 400, the void region 418 may eventually be filled with the second material 122. However, during deposition of the first material 120, the void region 418 remains empty. The slicer application 108 may process the slice 414 to generate multiple polygons, such as a first polygon 420, a second polygon 422, a third polygon 424, and a fourth polygon 426. The multiple polygons 420-426 may be generated and arranged such that the void region 418 is surrounded by the polygons 420-426, each polygon 420-426 is adjacent to the void region 418, and no polygon 420-426 includes an internal void region. Thus, each polygon 420-426 may be continuous (without spaces, openings, or holes), so that each polygon 420-426 can be printed using continuous lines thereby limiting starting and stopping a corresponding printhead.
The second slice 406 may also be processed further. For example, the second slice 406 includes multiple regions of the first material 120 and a large gap region in which no material is deposited. In this case, the slicer application 108 may identify and separate the regions to generate separate stacks 430 and 432. Each separate stack 430, 432 may be treated as a separate layer for purposes of generating a tool path. For example, a tool path 434 may be generated for the first stack 430, and a tool path 436 may be generated for the second stack 432. Although not illustrated in
In a particular embodiment, tool paths for multiple slices of the sliced and tool pathed model 440 may be determined such that a continuous line of material extends between multiple layers. For example, as further described in
Additionally, in some embodiments, one material may be deposited on a nonplanar surface formed by another material. For example, the slicer application may generate a tool path for depositing the second material that extends across multiple layers of the first material, as illustrated in
Further, as described above and with reference to
Thus,
In the example illustrated in
In the example illustrated in
Additionally, the 3D printing device illustrated in
In
In a particular example, while the extruder 502 deposits the material to form the partial physical model 801, the second material 808 may sitting unused in the extruder 802. Accordingly, as illustrated in
The method 1500 includes, at 1502, obtaining model data representing a three-dimensional (3D) model of an object. For example, the processor 103 of
The method 1500 includes, at 1504, processing the model data to generate a set of commands to direct a 3D printer device to extrude a material to form a physical model associated with the object. The set of commands may be executable to cause an extruder of the 3D printer device to deposit a first portion of the material corresponding to a first portion of the physical model. The set of commands may also be executable to cause the 3D printer device to clean the extruder after depositing the first portion of the material. The set of commands may further be executable to cause the extruder of the 3D printer device to deposit a second portion of the material after cleaning the extruder, where the second portion of the material corresponds to a second portion of the physical model.
For example, processing the model data may include performing slicing operations, such as operations described with reference to
In some implementations, the method 1500 may also include storing data representing the set of commands, sending data representing the set of commands to the 3D printer via a communication interface, or both. For example, after the commands 109 of
In a first implementation, the set of commands is executable to cause the 3D printer device 101 to track a quantity of the material deposited to form the first portion of the physical model. In a second implementation, a slicer application (such as the slicer application 108) generating the set of commands may determine a quantity of the material that will be deposited to form the first portion of the physical model and may include a cleaning sequence in the set of commands based on the quantity of the material deposited satisfying a threshold. In either of these implementations, the set of commands may be executable to cause the 3D printer device 101 to clean the extruder based on the quantity of the material deposited satisfying a threshold. For example, in the first implementation, when one of the material counters 145 indicates that the first extruder 130 has deposits a threshold quantity of the first material 120, the first extruder 130 may be cleaned (e.g., to avoid buildup of material around an opening of the first extruder tip 131). In the second implementation, the set of commands may be arranged sequentially, and the first extruder 130 may be cleaned when the cleaning sequence is reached.
Alternately, the first implementation, the second implementation, or both, may be based on deposition time rather than quantity of material deposited. To illustrate, in the first implementation, the set of commands is executable to cause the 3D printer device 101 to track a deposition time associated with forming the first portion of the physical model. In a second implementation, a slicer application (such as the slicer application 108) generating the set of commands may determining a deposition time associated with forming the first portion of the physical model and may include a cleaning sequence in the set of commands based on the deposition time satisfying a threshold. In either of these implementations, the set of commands may be executable to cause the 3D printer device 101 to clean the extruder based on the deposition time satisfying a threshold. For example, in the first implementation, when one of the timers 144 indicates that the first extruder 130 has been depositing the first material for a threshold amount of time, the first extruder 130 may be cleaned.
In yet another implementation, the set of commands is executable, while a particular extruder (e.g., the first extruder 130) is in use, to cause the 3D printer device to track downtime of another extruder (e.g., the second extruder 132 of the Nth extruder 134 or
In some implementations, the set of commands is executable to cause the 3D printer to mix two or more components to form the material. For example, the set of commands may be executable by the 3D printer device 101 to provide the first component 124 (e.g., a resin) and the second component 126 (e.g., a hardening agent) to the mixer 127 to form the mixture 128. In such implementations, the set of commands may cause the 3D printer device to clean the extruder based on the time since mixing satisfying a threshold. For example, the two or more components may begin to cure upon mixing, and the threshold may be based on a cure time of the mixture. In such implementations, the material extruded to form the first portion of the physical model may include or correspond to the mixture.
Alternatively, in a particular embodiment, the mixture may be used by a second extruder. In this embodiment, the set of commands may be executable to cause the 3D printer device to clean the second extruder after depositing the first portion of the material and before depositing the second portion of the material.
In some implementations, the set of commands is executable to cause the 3D printer device to deposit a second material after depositing the first portion of the material and before depositing the second portion of the material. The second material may be chemically distinct from the material. For example, the 3D model may include a first model portion representing a matrix material (e.g., a first material) and a second model portion representing a filler material (e.g., a second material). In this example, processing the model data may include identifying a first region of the 3D model that includes the matrix material and a second region of the 3D model that includes the filler material. For some 3D models, at least a portion of the second region may be enveloped by at least a portion of the first region in the 3D model. In this example, the processing the model data may also include automatically modifying the model data to omit at least a portion of the matrix material from the first region of the 3D model. For example, a portion of the matrix material may be omitted to enable a second extruder tip to enter an opening in the matrix material to deposit the filler material. In this example, dimensions of the portion of the matrix material omitted from the first region of the 3D model may be determined based on physical dimensions of the second extruder.
The method 1600 includes, at 1602, obtaining model data representing a three-dimensional (3D) model of an object. For example, the processor 103 of
The method 1600 includes, at 1604, processing the model data to generate a set of commands to direct a 3D printer device to extrude one or more materials to form a physical model associated with the object. The set of commands may be executable to cause a first extruder of the 3D printer device to deposit a first portion of a first material corresponding to a first portion of the physical model. The set of commands may also be executable to cause the 3D printer device to clean a second extruder of the 3D printer after depositing the portion of the first material.
For example, processing the model data may include performing slicing operations, such as operations described with reference to
In some implementations, the method 1600 may also include storing data representing the set of commands, sending data representing the set of commands to the 3D printer via a communication interface, or both. For example, after the commands 109 of
In a first implementation, the set of commands is executable to cause the 3D printer device 101 to track a quantity of the first material deposited to form the first portion of the physical model. In a second implementation, a slicer application (such as the slicer application 108) generating the set of commands may determine a quantity of the first material that will be deposited to form the first portion of the physical model and may include a cleaning sequence in the set of commands based on the quantity of the first material deposited satisfying a threshold. In either of these implementations, the set of commands may be executable to cause the 3D printer device 101 to clean the second extruder based on the quantity of the material deposited satisfying a threshold. For example, in the first implementation, when one of the material counters 145 indicates that the first extruder 130 has deposits a threshold quantity of the first material 120, the second extruder 132 may be cleaned. In the second implementation, the set of commands may be arranged sequentially, and the second extruder 132 may be cleaned when the cleaning sequence is reached.
Alternately, the first implementation, the second implementation, or both, may be based on deposition time rather than quantity of material deposited. To illustrate, in the first implementation, the set of commands is executable to cause the 3D printer device 101 to track a deposition time associated with forming the first portion of the physical model. In a second implementation, a slicer application (such as the slicer application 108) generating the set of commands may determining a deposition time associated with forming the first portion of the physical model and may include a cleaning sequence in the set of commands based on the deposition time satisfying a threshold. In either of these implementations, the set of commands may be executable to cause the 3D printer device 101 to clean the second extruder based on the deposition time of the first extruder satisfying a threshold. For example, in the first implementation, when one of the timers 144 indicates that the first extruder 130 has been depositing the first material for a threshold amount of time, the second extruder 132 may be cleaned.
In yet another implementation, the set of commands is executable, while the first extruder 130 is in use, to cause the 3D printer device 101 to track downtime of the second extruder 132, which is not in use and to clean the second extruder 132 based on the downtime of the second extruder 132 satisfying a threshold.
In some implementations, the set of commands is executable to cause the 3D printer device to mix two or more components to form the first material or to form a second material used by the second extruder. For example, the set of commands may be executable by the 3D printer device 101 to provide the first component 124 (e.g., a resin) and the second component 126 (e.g., a hardening agent) to the mixer 127 to form the mixture 128. In such implementations, the set of commands may cause the 3D printer device to clean the second extruder based on the time since mixing satisfying a threshold. In an embodiment, the two or more components may begin to cure upon mixing, and the threshold may be based on a cure time of the mixture. The mixture may be used by a second extruder. In this embodiment, the set of commands may be executable to cause the 3D printer device to clean the second extruder after depositing the first portion of the first material and before depositing a second portion of the first material.
In some implementations, the set of commands is executable to cause the 3D printer device to deposit a second material after depositing the first portion of the first material and before depositing a second portion of the first material. The second material may be chemically distinct from the first material. For example, the 3D model may include a first model portion representing a matrix material (e.g., a first material) and a second model portion representing a filler material (e.g., a second material). In this example, processing the model data may include identifying a first region of the 3D model that includes the matrix material and a second region of the 3D model that includes the filler material. For some 3D models, at least a portion of the second region may be enveloped by at least a portion of the first region in the 3D model. In this example, the processing the model data may also include automatically modifying the model data to omit at least a portion of the matrix material from the first region of the 3D model. For example, a portion of the matrix material may be omitted to enable a second extruder tip to enter an opening in the matrix material to deposit the filler material. In this example, dimensions of the portion of the matrix material omitted from the first region of the 3D model may be determined based on physical dimensions of the second extruder.
The method 1700 includes, at 1702, depositing, using a first extruder of a three-dimensional (3D) printer device, a first portion of a first material corresponding to a first portion of a physical model of an object. For example, the 3D printer device 101 of
The method 1700 includes, at 1704, cleaning the first extruder after depositing the first portion of the first material. For example, the first extruder 130 may be cleaned at the cleaning station 136 after the first extruder deposits the first material 120 to form a first portion of a physical model of an object. As another example, after the partial physical model 801 is formed as illustrated in
The method 1700 also includes, at 1706, after cleaning the first extruder, depositing, using the first extruder, a second portion of the first material, the second portion of the first material corresponding to a second portion of the physical model. For example, the first extruder 130 may be may be used to deposit the first material 120 to form a second portion of a physical model of an object after the first extruder 130 is cleaned. As another example, after the first extruder is cleaned, as illustrated in
In some implementations, the method 1700 may also include storing, at a memory of the 3D printer device, data representing a set of commands to form the physical model, sending data representing the set of commands via a communication interface, or both. For example, after the commands 109 of
In a particular embodiment, the method 1700 includes tracking a quantity of the first material deposited to form the first portion of the physical model. In this embodiment, the first extruder may be cleaned based on the quantity of the first material deposited satisfying a threshold.
In a particular embodiment, the method 1700 includes tracking a deposition time associated with forming the first portion of the physical model. In this embodiment, the first extruder may be cleaned based on the deposition time satisfying a threshold.
In a particular embodiment, the method 1700 includes tracking downtime of a second extruder of the 3D printer device. In this embodiment, the first extruder may be cleaned based on the downtime of the second extruder satisfying a threshold.
In a particular embodiment, the method 1700 includes mixing two or more components to form the first material and tracking a time since mixing. In this embodiment, the first extruder may be cleaned based on the time since mixing satisfying a threshold. For example, the two or more components may include a resin and a hardening agent that begin to cure upon mixing. In this example, the threshold may be based on a cure time of a mixture including the two or more components. Mixing the two or more components may include dispensing a resin from a first container of the 3D printer device into a mixer of the 3D printer device and dispensing a hardening agent from a second container of the 3D printer device into the mixer. The resin and the hardening agent may be mixed in the mixer, and the mixer may be in fluid communication with the first extruder.
In a particular embodiment, the method 1700 includes mix two or more components to form a second material associated with a second extruder of the 3D printer device and tracking a time since mixing. In this embodiment, the first extruder may be cleaned based on the time since mixing satisfying a threshold. For example, the two or more components may include a resin and a hardening agent that begin to cure upon mixing, and the threshold may be based on a cure time of a mixture. In this example, the method 1700 may include cleaning the second extruder after depositing the first portion of the first material and before depositing the second portion of the first material.
The method 1700 may also or in the alternative include, after depositing the first portion of the first material and before depositing the second portion of the first material depositing a second material using a second extruder of the 3D printer device. The second material may be chemically distinct from the first material.
The method 1800 includes, at 1802, depositing, using a first extruder of a three-dimensional (3D) printer device, a portion of a first material to form a first portion of a physical model. For example, the 3D printer device 101 of
The method 1800 includes, at 1804, after depositing the portion of the first material, cleaning a second extruder of the 3D printer device. For example, after the first extruder 130 is used to deposit the first material 120 to form the first portion of a physical model, the second extruder 132 may be cleaned. As another example, after the extruder 502 is used to form a first portion of a physical model of an object (such as the partial physical model 801
In some implementations, the method 1800 may also include storing, at a memory of the 3D printer device, data representing a set of commands to form the physical model, sending data representing the set of commands via a communication interface, or both. For example, after the commands 109 of
In a particular embodiment, the method 1800 includes tracking a quantity of the first material deposited to form the first portion of the physical model. In this embodiment, the second extruder may be cleaned based on the quantity of the first material deposited satisfying a threshold.
In a particular embodiment, the method 1800 includes tracking a deposition time associated with forming the first portion of the physical model. In this embodiment, the second extruder may be cleaned based on the deposition time satisfying a threshold.
In a particular embodiment, the method 1800 includes tracking downtime of the second extruder of the 3D printer device. In this embodiment, the second extruder may be cleaned based on the downtime of the second extruder satisfying a threshold.
In a particular embodiment, the method 1800 includes mixing two or more components to form the first material and tracking a time since mixing. In this embodiment, the first extruder may be cleaned based on the time since mixing satisfying a threshold. For example, the two or more components may include a resin and a hardening agent that begin to cure upon mixing. In this example, the threshold may be based on a cure time of a mixture including the two or more components. Mixing the two or more components may include dispensing a resin from a first container of the 3D printer device into a mixer of the 3D printer device and dispensing a hardening agent from a second container of the 3D printer device into the mixer. The resin and the hardening agent may be mixed in the mixer, and the mixer may be in fluid communication with the first extruder.
In a particular embodiment, the method 1800 includes mix two or more components to form the first material and tracking a time since mixing. In this embodiment, the second extruder may be cleaned based on the time since mixing satisfying a threshold. For example, the two or more components may include a resin and a hardening agent that begin to cure upon mixing, and the threshold may be based on a cure time of the mixture. In this example, the method 1800 may include cleaning the second extruder after depositing the first portion of the first material.
In a particular embodiment, the method 1800 includes mix two or more components to form a second material associated with the second extruder and tracking a time since mixing. In this embodiment, the second extruder may be cleaned based on the time since mixing satisfying a threshold. For example, the two or more components may include a resin and a hardening agent that begin to cure upon mixing, and the threshold may be based on a cure time of the mixture. In this example, the method 1800 may include cleaning the second extruder after depositing the first portion of the first material.
The method 1800 may also or in the alternative include, after depositing the first portion of the first material and before depositing a second portion of the first material depositing a second material using a second extruder of the 3D printer device. The second material may be chemically distinct from the first material.
The method 1900 includes, at 1902, moving an extruder of a 3D printer device relative to a deposition platform of the 3D printer device during deposition a material (e.g., a polymer) to form a portion of a first line. For example, one or more of the extruders 130, 132, 134 of
The method 1900 includes, at 1904, after depositing a portion of the material corresponding to a first end of the first line, moving the extruder back along the first line and concurrently moving the extruder away from the deposition platform. For example, after depositing end of a line, one or more of the extruders 130, 132, 134 of
The method 1900 may also include reducing an extrusion flow rate of the extruder as the extruder moves away from the deposition platform. For example, when the extruder is a paste extruder or syringe type extruder, pressure applied to a plunger of the extruder may be reduced as the extruder moves away from the deposition platform. As another example, when the extruder is a filament-fed extruder, a feed rate of the filament may be reduced as the extruder moves away from the deposition platform.
In a particular embodiment, the method 1900 may include forming a physical model by depositing multiple lines of the material including the first line. For example, depositing the multiple lines may include forming a base layer of the material on the deposition platform and stacking multiple layers of the material on the base layer. As another example, depositing the multiple lines may include forming a first stack of multiple layers of the material at a first location relative to the deposition platform and after forming the first stack, forming a second stack of multiple layers of the material at a second location relative to the deposition platform. In this example, the first stack may be formed to a height determined based on a physical configuration of the 3D printer device before the second stack is formed. The physical configuration of the 3D printer device may include or correspond to a distance between an extruder tip of the extruder and a support member coupled to the extruder. To illustrate, in
In a particular embodiment, the method 1900 may include depositing multiple layers of the material including the first line to form a first portion of a physical model defining a non-planar surface and using a second extruder of the 3D printer device to deposit at least one additional material on the non-planar surface to form a second portion of the physical model. For example, after the extruder 502 is used to deposit a first material to form the non-planer surface 852 of
The method 2000 includes, at 2002, during extrusion of a material (e.g., a polymer) by an extruder of a three-dimensional (3D) printer device, moving the extruder relative to a deposition platform of the 3D printer device. For example, one or more of the extruders 130, 132, 134 of
The method 2000 includes, at 2004, during movement of the extruder, adjusting an extrusion rate of the extruder based on an acceleration rate of relative motion of the extruder and the deposition platform. For example, as described with reference to
In a particular embodiment, the method 2000 may include forming a physical model by depositing multiple lines of the material including the first line. For example, depositing the multiple lines may include forming a base layer of the material on the deposition platform and stacking multiple layers of the material on the base layer. As another example, depositing the multiple lines may include forming a first stack of multiple layers of the material at a first location relative to the deposition platform and after forming the first stack, forming a second stack of multiple layers of the material at a second location relative to the deposition platform. In this example, the first stack may be formed to a height determined based on a physical configuration of the 3D printer device before the second stack is formed. The physical configuration of the 3D printer device may include or correspond to a distance between an extruder tip of the extruder and a support member coupled to the extruder. To illustrate, in
In a particular embodiment, the method 2000 may include depositing multiple layers of the material including the first line to form a first portion of a physical model defining a non-planar surface and using a second extruder of the 3D printer device to deposit at least one additional material on the non-planar surface to form a second portion of the physical model. For example, after the extruder 502 is used to deposit a first material to form the non-planer surface 852 of
The method 2100 includes, at 2102, obtaining model data representing a three-dimensional (3D) model of an object. For example, the processor 103 of
The method 2100 includes, at 2104, processing the model data to generate a set of commands to direct a 3D printer device to extrude a material (e.g., a polymer) to form a physical model associated with the object. The set of commands includes one or more first commands to cause relative motion of an extruder of the 3D printer device and a deposition platform of the 3D printer device during deposition a first portion of the material to form a portion of a first line. The one or more first commands are further executable to, after depositing a second portion of the material corresponding to a first end of the first line, cause relative motion of the extruder and the deposition platform such that the extruder moves back along the first line while the extruder concurrently moves away from the deposition platform. For example, after depositing an end of a line, one or more of the extruders 130, 132, 134 of
The set of commands may also include one or more second commands to reduce an extrusion flow rate of the extruder as the extruder moves back along the first line and away from the deposition platform. For example, when the extruder is a paste extruder or syringe type extruder, the one or more second commands may cause pressure applied to a plunger of the extruder to be reduced as the extruder moves away from the deposition platform. As another example, when the extruder is a filament-fed extruder, the one or more second commands may cause a feed rate of the filament to be reduced as the extruder moves away from the deposition platform.
In a particular embodiment, the set of commands may be executable to cause the 3D printer device to form a physical model by depositing multiple lines of the material including the first line. For example, depositing the multiple lines may include forming a base layer of the material on the deposition platform and stacking multiple layers of the material on the base layer. As another example, depositing the multiple lines may include forming a first stack of multiple layers of the material at a first location relative to the deposition platform and after forming the first stack, forming a second stack of multiple layers of the material at a second location relative to the deposition platform. In this example, the first stack may be formed to a height determined based on a physical configuration of the 3D printer device before the second stack is formed. The physical configuration of the 3D printer device may include or correspond to a distance between an extruder tip of the extruder and a support member coupled to the extruder. To illustrate, in
In a particular embodiment, the set of commands may be executable to cause the 3D printer device to deposit multiple layers of the material including the first line to form a first portion of a physical model defining a non-planar surface and to cause the 3D printer device to use a second extruder to deposit at least one additional material on the non-planar surface to form a second portion of the physical model. For example, after the extruder 502 is used to deposit a first material to form the non-planer surface 852 of
In a particular embodiment, the set of commands may be executable to cause the 3D printer device to form the physical model by stacking multiple layers of the material, where the 3D model defines a void region within an area corresponding to at least one layer of the multiple layers. In this embodiment, the set of commands may cause the 3D printer device to form the at least one layer as a set of polygons adjacent to a location corresponding to the void region. For example, the set of polygons may be formed such that no polygon of the set of polygons circumscribes the location corresponding to the void region. To illustrate, as shown in
The method 2200 includes, at 2202, obtaining model data representing a three-dimensional (3D) model of an object. For example, the processor 103 of
The method 2200 includes, at 2204, processing the model data to generate a set of commands to direct a 3D printer device to extrude a material (e.g., a polymer) to form a physical model associated with the object. The set of commands includes one or more first commands to cause relative motion of an extruder of the 3D printer device and a deposition platform of the 3D printer device during deposition of a portion of the material corresponding to a line. The set of commands further includes one or more second commands to adjust an extrusion rate of the extruder based on an acceleration rate of the relative motion. For example, the set of commands may be executable to cause an extrusion rate of one of more of the extruders 130, 132, 134 to be adjusted based on an acceleration rate of the extruder, as described further with reference to
In some implementations, the one or more first commands define a movement rate of the relative motion, such as a movement rate of the extruder. In such implementations, the acceleration rate of the relative motion may be determined based on settings of the 3D printer device. For example, the settings 150 of
In a particular embodiment, the set of commands may be executable to cause the 3D printer device to form a physical model by depositing multiple lines of the material including the first line. For example, depositing the multiple lines may include forming a base layer of the material on the deposition platform and stacking multiple layers of the material on the base layer. As another example, depositing the multiple lines may include forming a first stack of multiple layers of the material at a first location relative to the deposition platform and after forming the first stack, forming a second stack of multiple layers of the material at a second location relative to the deposition platform. In this example, the first stack may be formed to a height determined based on a physical configuration of the 3D printer device before the second stack is formed. The physical configuration of the 3D printer device may include or correspond to a distance between an extruder tip of the extruder and a support member coupled to the extruder. To illustrate, in
In a particular embodiment, the set of commands may be executable to cause the 3D printer device to deposit multiple layers of the material including the first line to form a first portion of a physical model defining a non-planar surface and to cause the 3D printer device to use a second extruder to deposit at least one additional material on the non-planar surface to form a second portion of the physical model. For example, after the extruder 502 is used to deposit a first material to form the non-planer surface 852 of
In a particular embodiment, the set of commands may be executable to cause the 3D printer device to form the physical model by stacking multiple layers of the material, where the 3D model defines a void region within an area corresponding to at least one layer of the multiple layers. In this embodiment, the set of commands may cause the 3D printer device to form the at least one layer as a set of polygons adjacent to a location corresponding to the void region. For example, the set of polygons may be formed such that no polygon of the set of polygons circumscribes the location corresponding to the void region. To illustrate, as shown in
The illustrations of the examples described herein are intended to provide a general understanding of the structure of the various implementations. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other implementations may be apparent to those of skill in the art upon reviewing the disclosure. Other implementations may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. For example, method operations may be performed in a different order than shown in the figures or one or more method operations may be omitted. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.
Moreover, although specific examples have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar results may be substituted for the specific implementations shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various implementations. Combinations of the above implementations, and other implementations not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.
The Abstract of the Disclosure is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single implementation for the purpose of streamlining the disclosure. Examples described above illustrate but do not limit the disclosure. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the present disclosure. As the following claims reflect, the claimed subject matter may be directed to less than all of the features of any of the disclosed examples. Accordingly, the scope of the disclosure is defined by the following claims and their equivalents.
Claims
1. A three-dimensional (3D) printer device comprising:
- an extruder configured to deposit a material on a deposition platform;
- an actuator coupled to at least one of the extruder or the deposition platform; and
- a controller coupled to the actuator, the controller configured to cause the extruder to deposit a first portion of the material corresponding to a first line, and after depositing a second portion of the material corresponding to a first end of the first line, to cause relative motion of the extruder and the deposition platform such that the extruder moves back along the first line while the extruder concurrently moves away from the deposition platform.
2. The 3D printer of claim 1, wherein the controller is further configured to reduce an extrusion flow rate of the extruder as the extruder moves away from the deposition platform.
3. The 3D printer of claim 2, wherein the extruder is a syringe extruder, and wherein the extrusion flow rate is reduced by decreasing pressure applied to a plunger of the syringe extruder.
4. The 3D printer of claim 1, wherein the material includes a polymer.
5. The 3D printer of claim 1, wherein the controller is further configured to send signals to the actuator and the extruder to control formation of a physical model of an object by forming a first stack of multiple layers of the material at a first location relative to the deposition platform before forming a second stack of multiple layers of the material at a second location relative to the deposition platform.
6. The 3D printer of claim 5, wherein the controller is configured to cause the first stack to be formed to a height determined based on a physical configuration associated with the extruder before beginning formation of the second stack.
7. The 3D printer of claim 6, wherein the physical configuration corresponds to a distance between an extruder tip and a support member coupled to the extruder.
8. The 3D printer of claim 1, further comprising a second extruder, wherein the controller is configured to cause the extruder to deposit multiple layers of the material to form a first portion of a physical model defining a non-planar surface and to cause the second extruder to deposit at least one additional material on the non-planar surface to form a second portion of the physical model.
9. The 3D printer of claim 1, wherein the first line forms at least a portion of a first layer and forms at least a portion of a second layer, wherein the second layer is stacked on the first layer.
10. A three-dimensional (3D) printer device comprising:
- an extruder configured to deposit a material on a deposition platform;
- an actuator coupled to at least one of the extruder or the deposition platform; and
- a controller coupled to the actuator, the controller configured to cause the actuator to cause relative motion of the extruder and the deposition platform during deposition of a portion of the material corresponding to a line and to adjust a flow rate of the extruder based on an acceleration rate of the relative motion.
11. The 3D printer of claim 10, wherein the extruder is a syringe extruder, and wherein the flow rate of the extruder is adjusted by changing pressure applied to a plunger of the syringe extruder.
12. The 3D printer of claim 10, wherein the material includes a polymer.
13. The 3D printer of claim 10, wherein the controller is further configured to send signals to the actuator and the extruder to control formation of a physical model of an object by forming a first stack of multiple layers of the material at a first location relative to the deposition platform before forming a second stack of multiple layers of the material at a second location relative to the deposition platform.
14. The 3D printer of claim 13, wherein the controller is configured to cause the first stack to be formed to a height determined based on a physical configuration associated with the extruder before beginning formation of the second stack.
15. The 3D printer of claim 14, wherein the physical configuration corresponds to a distance between an extruder tip and a support member coupled to the extruder.
16. The 3D printer of claim 10, further comprising a second extruder, wherein the controller is configured to cause the extruder to deposit multiple layers of the material to form a first portion of a physical model defining a non-planar surface and to cause the second extruder to deposit at least one additional material on the non-planar surface to form a second portion of the physical model.
17. The 3D printer of claim 10, wherein the line forms at least a portion of a first layer and forms at least a portion of a second layer, wherein the second layer is stacked on the first layer.
18. A method comprising:
- obtaining model data representing a three-dimensional (3D) model of an object; and
- processing the model data to generate a set of commands to direct a 3D printer device to extrude a material to form a physical model associated with the object, the set of commands including one or more first commands to cause relative motion of an extruder of the 3D printer device and a deposition platform of the 3D printer device during deposition a first portion of the material to form a portion of a first line, and after depositing a second portion of the material corresponding to a first end of the first line, to cause relative motion of the extruder and the deposition platform such that the extruder moves back along the first line while the extruder concurrently moves away from the deposition platform.
19. The method of claim 18, wherein the set of commands further includes one or more second commands to reduce an extrusion flow rate of the extruder as the extruder moves back along the first line and away from the deposition platform.
20. The method of claim 18, wherein the material includes a polymer.
21. The method of claim 18, wherein the set of commands is executable by the 3D printer device to form the physical model by depositing a base layer of the material on the deposition platform and by stacking multiple layers of the material on the base layer, and wherein the set of commands causes the 3D printer device to form a first stack of multiple layers of the material at a first location relative to the deposition platform before forming a second stack of multiple layers of the material at a second location relative to the deposition platform.
22. The method of claim 21, wherein the first stack includes a first portion of the base layer deposited at the first location and includes a first plurality of layers stacked on the first portion of the base layer, and wherein the second stack includes a second portion of the base layer deposited at the second location and includes a second plurality of layers stacked on the second portion of the base layer.
23. The method of claim 21, wherein the first stack includes a first plurality of layers stacked above the deposition platform at the first location, and wherein the second stack includes a second plurality of layers stacked above the deposition platform at the second location.
24. The method of claim 21, wherein, before forming the second stack, the first stack is formed to a height determined based on a physical configuration of the 3D printer device.
25. The method of claim 24, wherein the physical configuration corresponds to a distance between an extruder tip and a support member.
26. The method of claim 18, wherein the 3D printer device is configured to extrude the material and at least one additional material, and wherein the set of commands is executable by the 3D printer device to deposit multiple layers of the material to form a first portion of the physical model defining a non-planar surface before depositing the at least one additional material on the non-planar surface to form a second portion of the physical model.
27. The method of claim 18, wherein the set of commands is executable by the 3D printer device to form the physical model by stacking multiple layers of the material, wherein the 3D model defines a void region within an area corresponding to at least one layer of the multiple layers, and wherein the set of commands causes the 3D printer device to form the at least one layer as a set of polygons adjacent to a location corresponding to the void region.
28. The method of claim 27, wherein no polygon of the set of polygons circumscribes the location corresponding to the void region.
29. The method of claim 18, wherein the set of commands is executable by the 3D printer device to form the physical model by stacking multiple layers of the material, wherein the first line forms at least a portion of a first layer of the multiple layers and forms at least a portion of a second layer of the multiple layers, wherein the second layer is stacked on the first layer.
30. A method comprising:
- obtaining model data representing a three-dimensional (3D) model of an object; and
- processing the model data to generate a set of commands to direct a 3D printer device to extrude a material to form a physical model associated with the object, the set of commands including one or more first commands to cause relative motion of an extruder of the 3D printer device and a deposition platform of the 3D printer device during deposition of a portion of the material corresponding to a line, the set of commands further including one or more second commands to adjust an extrusion rate of the extruder based on an acceleration rate of the relative motion.
31. The method of claim 30, wherein the one or more first commands define a movement rate of the relative motion, and the acceleration rate of the relative motion is determined based on settings of the 3D printer device.
32. The method of claim 30, wherein the one or more first commands define a movement rate of the relative motion, and the acceleration rate of the relative motion is determined based on a hardware configuration of the 3D printer device.
33. The method of claim 30, wherein the material includes a polymer.
34. The method of claim 30, wherein the set of commands is executable by the 3D printer device to form the physical model by depositing a base layer of the material on the deposition platform and by stacking multiple layers of the material on the base layer, and wherein the set of commands causes the 3D printer device to form a first stack of multiple layers of the material at a first location relative to the deposition platform before forming a second stack of multiple layers of the material at a second location relative to the deposition platform.
35. The method of claim 34, wherein the first stack includes a first portion of the base layer deposited at the first location and includes a first plurality of layers stacked on the first portion of the base layer, and wherein the second stack includes a second portion of the base layer deposited at the second location and includes a second plurality of layers stacked on the second portion of the base layer.
36. The method of claim 34, wherein the first stack includes a first plurality of layers stacked above the deposition platform at the first location, and wherein the second stack includes a second plurality of layers stacked above the deposition platform at the second location.
37. The method of claim 34, wherein, before forming the second stack, the first stack is formed to a height determined based on a physical configuration of the 3D printer device.
38. The method of claim 37, wherein the physical configuration corresponds to a distance between an extruder tip and a support member.
39. The method of claim 30, wherein the 3D printer device is configured to extrude the material and at least one additional material, and wherein the set of commands is executable by the 3D printer device to deposit multiple layers of the material to form a first portion of the physical model defining a non-planar surface before depositing the at least one additional material on the non-planar surface to form a second portion of the physical model.
40. The method of claim 30, wherein the set of commands is executable by the 3D printer device to form the physical model by stacking multiple layers of the material, wherein the 3D model defines a void region within an area corresponding to at least one layer of the multiple layers, and wherein the set of commands causes the 3D printer device to form the at least one layer as a set of polygons adjacent to a location corresponding to the void region.
41. The method of claim 40, wherein no polygon of the set of polygons circumscribes the location corresponding to the void region.
42. The method of claim 30, wherein the set of commands is executable by the 3D printer device to form the physical model by stacking multiple layers of the material, wherein a first line of the material forms at least a portion of a first layer of the multiple layers and at least a portion of a second layer of the multiple layers, wherein the second layer is stacked on the first layer.
43. A method comprising:
- moving an extruder of a three-dimensional (3D) printer device relative to a deposition platform of the 3D printer device during deposition a material to form a portion of a first line; and
- after depositing a portion of the material corresponding to a first end of the first line, moving the extruder back along the first line and concurrently moving the extruder away from the deposition platform.
44. The method of claim 43, further comprising reducing an extrusion flow rate of the extruder as the extruder moves away from the deposition platform.
45. The method of claim 43, wherein the material includes a polymer.
46. The method of claim 43, further comprising forming a physical model by depositing multiple lines of the material including the first line, wherein depositing the multiple lines includes:
- forming a base layer of the material on the deposition platform; and
- stacking multiple layers of the material on the base layer.
47. The method of claim 43, further comprising forming a physical model by depositing multiple lines of the material including the first line, wherein depositing the multiple lines includes:
- form a first stack of multiple layers of the material at a first location relative to the deposition platform; and
- after forming the first stack, forming a second stack of multiple layers of the material at a second location relative to the deposition platform.
48. The method of claim 47, wherein, before forming the second stack, the first stack is formed to a height determined based on a physical configuration of the 3D printer device.
49. The method of claim 48, wherein the physical configuration corresponds to a distance between an extruder tip of the extruder and a support member coupled to the extruder.
50. The method of claim 43, further comprising:
- depositing multiple layers of the material including the first line to form a first portion of a physical model defining a non-planar surface; and
- after depositing the multiple layers of the material, depositing, using a second extruder of the 3D printer device, at least one additional material on the non-planar surface to form a second portion of the physical model.
51. The method of claim 43, wherein the first line forms at least a portion of a first layer of multiple layers of a physical model and forms at least a portion of a second layer of the multiple layers, wherein the second layer is stacked on the first layer.
52. A method comprising:
- during extrusion of a material by an extruder of a three-dimensional (3D) printer device, moving the extruder relative to a deposition platform of the 3D printer device; and
- during movement of the extruder, adjusting an extrusion rate of the extruder based on an acceleration rate of relative motion of the extruder and the deposition platform.
53. The method of claim 52, wherein the material includes a polymer.
54. The method of claim 52, wherein extrusion of a material is used to form a physical model by depositing a base layer of the material on the deposition platform and by stacking multiple layers of the material on the base layer, and further comprising:
- forming a first stack of multiple layers of the material at a first location relative to the deposition platform; and
- after forming the first stack, forming a second stack of multiple layers of the material at a second location relative to the deposition platform.
55. The method of claim 54, wherein, before forming the second stack, the first stack is formed to a height determined based on a physical configuration of the 3D printer device.
56. The method of claim 55, wherein the physical configuration corresponds to a distance between an extruder tip and a support member coupled to the extruder.
57. The method of claim 52, further comprising:
- depositing multiple layers of the material to form a first portion of a physical model defining a non-planar surface; and
- after depositing the multiple layers of the material, depositing, using a second extruder of the 3D printer device, at least one additional material on the non-planar surface to form a second portion of the physical model.
58. The method of claim 52, wherein the material extruded during movement of the extruder forms at least a portion of a first layer of multiple layers of the material and forms at least a portion of a second layer of the multiple layers, wherein the second layer is stacked on the first layer.
Type: Application
Filed: Jul 22, 2016
Publication Date: Feb 23, 2017
Inventors: John Minardi (Somerville, MA), Travis Busbee (Somerville, MA), Jonathan Tran (Somerville, MA), Max Eskin (Somerville, MA)
Application Number: 15/217,529