Cellular Fabrication and Apparatus for Additive Manufacturing

Abstract

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create “scaffolding” or “skeletons” of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

Claims

1. An apparatus for constructing a cellular matrix structure, the apparatus comprising: a. an extruder for extruding cellular matrix structure components, the extruder further comprising a nozzle body comprising an extrudate pathway extending to an extrudate orifice in the nozzle body, the extrudate orifice comprising a multi-arm cross sectional shape; b. a multi-axis movement device for moving the extruder along multiple predetermined paths while the extruder is extruding structural components to place the structural components in desired positions and connected to selected ones of other components as the components are produced, and c. a controller for moving the extruder and controlling operation of the extruder.

2. The apparatus of claim 1, wherein the multi-arm cross sectional shape comprises a non-circular cross-sectional shape.

3. The apparatus of claim 1, wherein the multi-arm cross sectional shape comprises at least two arms extending away from a central portion of the multi-arm cross sectional shape.

4. The apparatus of claim 3, wherein the multi-arm cross sectional shape comprises a cross shape.

5. The apparatus of claim 3, wherein at least some of the arms of the multi-arm cross sectional shape include branches.

6. The apparatus of claim 5, wherein at least some of the branches are spaced apart from the central portion of the multi-arm cross sectional shape.

7. The apparatus of claim 5, wherein the multi-arm cross sectional shape shapes an extrudate such that the extrudate includes anchor portions for strengthening a mechanical bond between the extrudate and an infill material.

8. The apparatus of claim 3, wherein the nozzle body further comprises a coolant pathway extending at least partially through the nozzle body.

9. The apparatus of claim 8, wherein the coolant pathway is located at least partially between at least two of the arms of the multi-arm cross sectional shape.

10. An apparatus for constructing a cellular matrix structure, the apparatus comprising: a. an extruder for extruding cellular matrix structure components, the extruder further comprising a nozzle body comprising: (i) an extrudate pathway extending to an extrudate orifice in the nozzle body; and (ii) a coolant pathway extending at least partially through the nozzle body; b. a multi-axis movement device for moving the extruder along multiple predetermined paths while the extruder is extruding structural components to place the structural components in desired positions and connected to selected ones of other components as the components are produced, and c. a controller for moving the extruder and controlling operation of the extruder.

11. The apparatus of claim 10, wherein the coolant pathway is configured to carry a coolant and wherein the extrudate pathway is configured to carry an extrudate, wherein the coolant is configured to at least partially solidify the extrudate while the extrudate is in the extrudate pathway.

12. The apparatus of claim 10, wherein the coolant pathway is configured to carry a coolant and wherein the extrudate pathway is configured to carry an extrudate, wherein the coolant is configured to at least partially solidify the extrudate after the extrudate is extruded from the extrudate orifice.

13. The apparatus of claim 10, wherein the coolant pathway is configured to carry a coolant and wherein the extrudate pathway is configured to carry an extrudate, wherein the coolant is configured to at least partially solidify the extrudate while the extrudate is in the extrudate pathway and after the extrudate is extruded from the extrudate orifice.

14. The apparatus of claim 10, wherein the coolant pathway extends to a coolant orifice such that coolant will contact an extrudate at the extrudate orifice.

15. The apparatus of claim 10, wherein the coolant pathway extends to a coolant orifice such that coolant will contact an extrudate downstream of the extrudate orifice.

16. The apparatus of claim 10, wherein the coolant pathway includes at least a portion with a cross sectional shape that extends at least partially around a portion of the extrudate pathway.

17. The apparatus of claim 10, wherein the apparatus further comprises a heating fluid pathway.

18. The apparatus of claim 17, wherein the heating fluid pathway extends to a heating fluid orifice in the nozzle body such that a heating fluid will contact extrudate outside of the nozzle body in a heating zone.

19. The apparatus of claim 18, wherein the heating zone is located at a connection point between the extrudate and a second structure.

20. The apparatus of claim 19, wherein the second structure is a second segment of extruded material.

21. The apparatus of claim 10, wherein the apparatus further comprises a marking medium pathway configured to direct a marking medium onto a portion of an extrudate extruded by the extruder.

22. The apparatus of claim 10, wherein the multi-axis movement device comprises a robotic arm movable in at least three degrees of freedom.

23. The apparatus of claim 10, wherein the extruder comprises an extrusion screw.

24. The apparatus of claim 10, wherein the apparatus is configured to extrude extrudate onto a non-horizontal, a vertical, or a ceiling-located build platform.

25. The apparatus of claim 10, wherein the apparatus is configured to extrude extrudate onto a non-planar build platform or non-planar object.

26. The apparatus of claim 10, wherein the apparatus is configured to extrude an extrudate into areas where the extrudate is not directly supported underneath.

27. The apparatus of claim 10, wherein the apparatus further comprises a sensor configured to sense a change in at least one of position and orientation of extruded material after extrusion.

28. The apparatus of claim 10, wherein the controller is configured to adjust a coolant flow of the apparatus.

29. The apparatus of claim 28, wherein adjusting the coolant flow comprises adjusting a flow rate or a flow location of a coolant.

30. The apparatus of claim 29, wherein adjusting the coolant flow comprises adjusting a solidification speed of an extrudate.

31. The apparatus of claim 10, wherein the extrudate orifice comprising a multi-arm cross sectional shape, wherein the coolant pathway comprises a plurality of coolant pathways, and wherein at least one of the coolant pathways is at least partially located between two arms of the multi-arm cross sectional shape.

32. The apparatus of claim 10, wherein the extruder is configured to co-extrude structural components comprising a first material and a second material.

33. The apparatus of claim 32, wherein the first material comprises a first stiffening rate and the second material comprises a second stiffening rate, the second stiffening rate being faster than the first stiffening rate.

34. A three dimensional object comprising: a cellular matrix structure comprising a framework of a plurality of extrudate members intersecting at joints, at least some of the individual extrudate members comprising multi-arm cross sectional shapes, the framework further defining interstitial spaces.

35. The three dimensional object of claim 34, further comprising filler material in at least some of the interstitial spaces.

36. The three dimensional object of claim 34, wherein the extrudate members define a plurality of cells, the plurality of cells defining a plurality of three dimensional trusses.

37. The three dimensional object of claim 36, wherein the three dimensional trusses comprise at least one of load bearing trusses or stiffening trusses of the three dimensional object.

38. The three dimensional object of claim 36, further comprising a septum dividing a first group of the cells from a second group of the cells, wherein a first type of filler is in or excluded from interstitial spaces of the first group of cells and a second type of filler is in or excluded from interstitial spaces of the second group of cells.

39. The three dimensional object of claim 34, further comprising a septum separating a first region of the three dimensional object from a second region of the three dimensional object.

40. The three dimensional object of claim 34, wherein at least some of the individual extrudate members comprise a first extrudate material and a second extrudate material.

41. The three dimensional object of claim 40, wherein the second extrudate material at least partially surrounds the first extrudate material in cross section.

42. The three dimensional object of claim 34, wherein the object comprises a component of an airfoil, an airframe, a boat hull, or a satellite.

43. The three dimensional object of claim 34, wherein the extrudate members comprise a cross-linked polymer material.

44. The three dimensional object of claim 34, wherein the extrudate members comprise a polymer chain extender compound.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0110] Illustrative embodiments of the present invention are described in detail below with reference to the following drawing figures:

[0111] FIG. 1 is a perspective view of one embodiment of this invention.

[0112] FIG. 2 is axonometric view of an exemplary extruder mechanism of this invention.

[0113] FIG. 3 is an exploded axonometric of the extruder mechanism shown in FIG. 2.

[0114] FIG. 4 is a section through the long axis of the extruder-shown in FIG. 2.

[0115] FIG. 5 is a view of one side of the extruder shown in FIG. 2.

[0116] FIG. 6 is a view of the front of the extruder shown in FIG. 2.

[0117] FIG. 7 is a top view of the extruder shown in FIG. 2.

[0118] FIG. 8 is a bottom view of the extruder shown in FIG. 2.

[0119] FIGS. 9-12 depict nozzle heat transfer variations.

[0120] FIG. 13 depicts alternative extrudate shapes.

[0121] FIG. 14 depicts a nozzle with multiple orifices.

[0122] FIG. 15 depicts a nozzle with multiple material sources.

[0123] FIG. 16 depicts a nozzle with multiple orifices supplied from multiple materials sources.

[0124] FIG. 17 depicts an exemplary nozzle showing feedstock in filament form.

[0125] FIG. 18 depict a nozzle that extrudes materials together with a fiber.

[0126] FIG. 19 is an exemplary isometric view of segments in accordance with this invention.

[0127] FIG. 20 is an isometric view of exemplary robot movement.

[0128] FIG. 21 is an isometric view of an exemplary wall illustrating programming ranges of patterns within a wall.

[0129] FIG. 22 is a perspective view of an object being constructed with a movement mechanism capable of multiple degrees of motion.

[0130] FIG. 23 depicts a mobile platform for manipulating an extruder.

[0131] FIG. 24 depicts a hand-held embodiment of an extruder of this invention.

[0132] FIGS. 25-30 are schematic depictions of exemplary cellular structures of various embodiments of this invention.

[0133] FIG. 31 is a schematic perspective view of a structure of an embodiment of this invention.

[0134] FIG. 32 is an isometric view is a mobile platform in use in accordance with an embodiment of this invention forming a wall structure.

[0135] FIG. 33 depicts steps of an exemplary method of this invention.

[0136] FIG. 34 is a diagram illustrating various configuration locations for a septum and added materials.

[0137] FIGS. 35a, 35b, and 35c are various example configurations of the septum and added materials.

[0138] FIG. 36 illustrates an enclosed septum in various arrangements.

[0139] FIG. 37 is a diagram illustrating freeform printing advantages.

[0140] FIG. 38 is a diagram of a nozzle orifice.

[0141] FIG. 39 shows several possible extrudate shapes and cooling configurations.

[0142] FIG. 40 is an axonometric view of cooling fluid flowing through channels formed within the extrudate.

[0143] FIG. 41 is an axonometric view of a nozzle with a cooling passage.

[0144] FIG. 42 is not shown.

[0145] FIGS. 43a, 43b, and 43c are diagrams that illustrate the effects of various cooling system configurations upon the extrudate.

[0146] FIGS. 44a, 44b, and 44c illustrate possible extrusion configurations which incorporate additional material to more rapidly stiffen the extrudate to become self-supporting.

[0147] FIG. 45 is a diagram illustrating the formation of a mechanical bond between a shaped extrusion profile and an infill material added to the cellular matrix.

[0148] FIG. 46 illustrates a nozzle marking target points for position detection.

[0149] FIG. 47 depicts a nozzle which facilitates heat welding of connections within the cellular matrix.

[0150] FIGS. 48a, 48b, 48c, and 48d are diagrams illustrating profiled laminar extrusion.

[0151] FIG. 49 depicts a nozzle with a bonding agent at connections within the cellular matrix.

DETAILED DESCRIPTION

[0152] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

Extruder

[0153] In one embodiment of this invention, depicted in FIG. 1, an extruder assembly 101 is manipulated by a robotic armature system 102 to fabricate a structure 103. The nozzle end 104 of extruder assembly 101 is moved along a pathway 105 while material is dispensed from the orifice 106 of the nozzle 104 at a controlled rate. Once the material exits the orifice 106 it is rapidly cooled by air jets that harden the extrudate to a solid that can be formed without support for a given segment length. As the extruder 101 dispenses material, the motion of the extruder through space at a controlled speed is coordinated with the extrusion rate such that material is dispensed along a pathway in a controlled manner. The rate of deposition may be faster or slower than the induced motion to create varying effects. The motion is programmed or controlled via computer 108 that is coupled to a controller 109 that controls the motion of the robot 102. Temperature is controlled by a thermostatic temperature controller 110 attached to the heating elements of the extruder 101. Air pressure and air movement are supplied by an air compressor 111 fed to the extruder via a hose 112. Material is fed to the extruder mechanism 101 from a supply source 113 via a material feed system 114.

[0154] As illustrated in FIGS. 2-8, an exemplary extruder 101 holds material 201 in pellet form temporarily in a hopper 202 that feeds the material into the barrel 203 of the extruder through an opening 204. Within the barrel 203 a screw 205 rotates to pulverize, partially melt, and dispense the material. The screw is preferably designed for the particular extrusion process in use. The rotation of the screw is driven by a motor assembly 206 that may include a gear assembly 207 to control the motor speed and a motor controller 208 to regulate the speed of the motor 206.

[0155] The motor 206 may be mounted to the thrust bearing assembly 209 with the motor drive shaft 210 connected to the screw by a coupling 211. The thrust bearing assembly contains means to resist the thrust of the screw with a rotational thrust bearing 212.

[0156] As the material is pushed along by the extrusion screw, heat is applied to facilitate the melting process by various means, such as resistance heater bands 213 mounted around the extruder at various locations. Other methods to add heat may include other resistance heat methods such as cartridge heaters, or coil heaters. Other methods such as heated air, heated fluids, vibratory, ultrasonic, infrared, direct current interaction or lasers may be used. Temperature may be monitored by thermocouples 214 and controlled thermostatically at each heater band 213.

[0157] A breaker plate 215 with holes in a variety of patterns may be used to generate back pressure in the barrel and ensure a consistent mixture in the extrudate. A shutoff valve 216 may be employed that controls the flow of the extrudate. Valve 216 may work in coordination with the pressures induced by the rotation of the screw 205 to open and close a spring loaded opening mechanism, or it may be controlled in other manners, such as pneumatically.

[0158] An extruder may be monitored as to location, temperature, flow rate and otherwise with great precision, enabling manipulation of the extruder and control of the extrudate it produces with similarly great precision. For instance, a pressure transducer may be used to monitor internal pressure within the barrel. Temperature sensors within the barrel and or within the melt may be used to precisely control the temperature of the material.

Nozzle

[0159] The nozzle 217 (sometimes called a “die”) forms the shape of the material and dispenses it from an orifice 218. The heat may be removed from the material by means of air flow 219 cooling through and out of the nozzle 217 through opening 220 so that the air flows around extrudate 221. The air may also be used to remove heat within the nozzle without flowing onto the extrudate 221.

[0160] FIGS. 9-12 depict structures that use other fluids that may also recirculate out of the nozzles and that may include supplementary heating and cooling systems. These fluid passageways may be internal or external to the nozzles.

[0161] FIG. 9 illustrates a system where a fluid 901 is introduced into the nozzle 217 that circulates around the material 201 while it is moving through the nozzle 217. This fluid then exits nozzle 217 and flows over the extrudate 221. The fluid may either be a liquid or a gas.

[0162] FIG. 10 employs a similar fluid as FIG. 9 except the fluid 901 re-circulates and does not flow over the extrudate 221. FIG. 11 illustrates a similar approach as FIGS. 9 and 10 but the fluid 901 exits the nozzle and does not flow directly onto the extrudate 221. FIG. 12 illustrates a similar approach as FIG. 9 except that the fluid 901 circulates external to the nozzle and does not flow within the nozzle proper. The fluid 901 may circulate around the nozzle and flow onto the extrudate 221.

[0163] Motor speed, valve operation, temperature control, and heat removal may all be controlled and operated in coordination with each other or may be controlled separately.

[0164] The shape of the extrudate 221 may be adjusted by various methods, either by changing nozzles, dynamically adjusting the shape of the extrudate 221, or changing the rate of motion causing the material to accumulate or stretch as shown in FIG. 13. The shape of the extrudate may be modulated to be thicker 1301 or thinner 1302 in certain areas or the cross section may be changed from one shape 1303 to another shape 1304 or 1305.

[0165] FIGS. 14, 15 and 16 depict nozzle variations, including nozzles that dispenses extrudate from multiple holes simultaneously, nozzles that dispenses extrudate from two components and or at different times in a connected or disconnected manner. FIG. 14 illustrates a nozzle 217 with multiple orifices 218 extruding from one material source 201. FIG. 15 illustrates a nozzle 217 with one orifice 218 combining multiple material sources 201a and 201b that may be mixed prior to exit from orifice 218 or extrude in a laminated format. FIG. 16 illustrates a nozzle 217 with multiple orifices 218a and 218b that are supplied from multiple materials sources 201a and 201b that may be controlled together or separately.

Filament

[0166] FIG. 17 depicts an alternative extruder assembly 1700 that operates similarly to a common 3D printer whereby filament 1701 is fed into a heating chamber 1702, is melted, and extruded from the nozzle 1703. The nozzle 1703 would work similarly to the description of nozzles in FIGS. 9-12, except that the material from which the extrudate is formed is initially in filament form rather than pellet form.

Materials

[0167] Among many other existing and yet-to-be-developed materials, ABS plastic resin becomes fluid within a range of temperatures but in a controlled manner depending on the desired result. ABS with a fibrous or other additive may be used to change certain properties of the extrudate. Various other thermoplastics may be utilized to achieve similar results.

[0168] Any other materials may be used that can be extruded through an orifice and then rapidly solidify. Some of these may be thermoplastic, thermoset, epoxies, wax, polymer, metallic, foam, organic, cementitious, ceramic, biological, or other existing and later-developed materials. Some such materials are fluids above certain temperatures and rapidly solidify when their temperature drops.

[0169] Other usable materials may solidify as a result of chemical processes such as two-part materials, like some epoxies that crosslink and solidify after the two parts are combined, or other materials that crosslink after introduction of a catalyst, or exposure to moisture or ultraviolet light. Some such materials bond to themselves, at least when contact occurs above certain temperatures or before chain linking or other chemical reactions have fully occurred. Other materials systems may utilize a structural extrudate and a separately supplied bonding material or agent dispensed at the points of contact of the structural extrudate, such as a cyanoacrylate or other fast-acting adhesive. One embodiment of this method is shown in FIG. 48.

[0170] One method of reinforcing the extrudate is through the addition of a continuous or broken strand(s) of fiber reinforcing. Common materials used for this may include glass fiber, ceramic fiber, metallic wire, or carbon fiber strands. As depicted in FIG. 18, the fiber 1801 is incorporated into the melt 1802 such that the melt may encapsulate the fiber 1801 strand to reinforce each segment of the cellular matrix fabricated from the fiber 1801 and melt 1802 extrudate 1803.

[0171] Other existing and future extrusion techniques may also be employed to combine materials or enhance extrusion, including use of a mandrel or air or other fluid or by, for instance, utilization of bladed sheet flow or blown film extrusion techniques.

Motion

[0172] Extruder nozzle motion may be accomplished in any way that places the nozzle where it needs to be at a particular time. In one embodiment, as generally depicted in FIG. 1, extruder and nozzle movement is provided by a multiple axis industrial robot 102. The extruder 101 is attached to the robot 102 by means of a bracket assembly 222 shown in FIGS. 2, 3, 4 and 6 that which mounts to the end of the armature 223 shown in FIGS. 4 and 6.

[0173] The robot 102 is programmatically controlled by a computer 108 to execute the motion necessary to create the desired cellular matrix pathways. One method for producing this motion is by drawing the cellular matrix in a CAD program that is then translated into a sequential motion process- to control the robot 102. This motion is programmed to include information that coordinates the extrusion speed, temperature control, cooling mechanism and other parameters for extrusion.

[0174] Such a basic motion control program allows the movement mechanism to move from one point to another point along a prescribed path at a certain speed as shown by reference to exemplary three dimensional shapes in FIGS. 19 and 20. While the robot 102 is executing such movement of the extruder 101 and attached nozzle 217, the extruder motor 208 may also be activated at a prescribed speed, a material shutoff valve 216 may be opened, temperature of various portions of the apparatus and the material may be monitored and heating or cooling mechanism(s) may be turned on or off as appropriate. The motion of the robot may pause to create (as shown in FIG. 20) a node 2001 or joint 2002 built up with the extrudate 2003. The cooling or heating systems may turn off or on to modulate solidity in the extrudate 2003 viscosity or other flow characteristics. Motor 206 speed may also be changed to increase or decrease the extrudate flow out of the extruder 101. The rate of extrusion, rate of motion, heat transfer, cooling, heating and fusing are coordinated to produce a solid filament of desired shape and size along the prescribed pathway bonded to other filaments or other structures where desired.

Sequence

[0175] As shown in FIGS. 19 and 20 the program sequence and resulting nozzle movement allows material to be added that connects to previously deposited material at joints without passing back through previously applied material. This programming determines the overall shape of the final structure along with all the interconnected sequential segments forming a part of it.

Segments

[0176] Each of these segments such as segments 2004 and 2005 in FIG. 20 may be derived by breaking down the cellular matrix into pathways such as the path 2-3 and the joint 1, 5. Each pathway is assigned characteristics such as speed of extrusion, speed of motion, temperature, and cooling. These characteristics determine how elements such as segments 2004 and 2005 and the resulting structure comprised by those elements will be built up. Once a region of the cellular matrix (like the cells depicted in FIGS. 19 and 20) is complete, additional material is added to build up the structure in a horizontal and/or vertical manner by the addition of more cells

Range Programming

[0177] Another method of building up the cellular matrix in lieu of discreet pathway programming is illustrated in FIG. 21. In this technique, certain patterns of material deposition 2101, 2102, or 2103 are applied to similarly structured volumes of space. The program may dictate the application of a certain cellular pattern over a particular range without having to program each discreet motion step. In this manner, a structure may be divided into ranges that would inform the pattern formation by the robot and the motion programming may be substantially simplified.

[0178] The example wall illustrated in FIG. 21 has certain physical characteristics and internal stresses as a result of its design. The application of the cellular matrix and resulting motion control programming may be algorithmically automated to respond to the geometry and stresses within the wall by allocating certain patterns of formation 2201, 2202, or 2203 to certain ranges within the wall. In an area of higher stress, geometry 2101 may be applied to range A1, but in an area of lower stress, geometry 2102 may be applied to range B2. This method of algorithmically responding to the necessary requirements of a given wall area may significantly simplify the programming and reduce material use by optimizing the internal structure for the stresses needed to be resisted.

Feedback Sensors

[0179] To ensure accuracy in the built structure, feedback and adjustment mechanisms may be employed that sense the actual conditions of the joints and other previously applied materials, as distinguished from the ideal designed conditions of the joints and previously applied material. Since deflection, material creep, wind, temperature, and other real world conditions will affect the previously extruded areas, methods to dynamically adjust the motion and extrusion parameters to accommodate these factors may be employed to increase the accuracy of the end result. Some of the methods may include range finding, optical feedback, motion sensing, photogrammetry, motion capture, sonar, lidar, among other feedback mechanisms.

Motion Methods

[0180] As shown in the drawings, alternative methods for moving the extruder may be employed. These may include, without limitation, a gantry system, CNC system, or traditional 3D printers with additional axes of control as illustrated in FIG. 22, hydraulic equipment as depicted in FIG. 23, or handheld versions of the extruder as shown in FIG. 24.

[0181] The explained above, purpose for the extruder and the movement mechanism is to connect points to create a pathway along which material is deposited. Each pathway is added to others to finally create the cellular matrix which makes up the internal structure of the final building or object.

Cellular Matrix

[0182] The cellular matrix is created by a applying a given cellular pattern to the internal volume of a solid as illustrated with the examples of FIGS. 25-30. The cellular pattern may be self-repeating or may be different from one cell or group of cells to another. Idealized versions of the structures of molecules, plant, animal, or human cells, minerals, foams, naturally occurring patterns, mathematical formulae, polyhedral, space frames, trusses or other patterns may be used to modularize the internal volume of the overall structure. The purpose of the cellular matrix is to create a balance between material used, space occupied, and strength derived from a certain pattern. The material, diameter, shape, and length of each extruded segment will determine the density of the cellular matrix. As with natural cellular constructions, various qualities may be modulated to achieve various results but may include structures to add strength, separation, flexibility, openness, rigidity, and specificity of function among other beneficial qualities.

[0183] In addition to the above-described and illustrated methods of construction of the cellular matrix, there are other methods of fabricating the cellular matrix that do not include extrusion, but may produce substantially similar end results. For instance, crystallizing foam, growing organic structures, the drying process within a medium, modular bricks, connected faces of a panelized structure or using conventional additive manufacturing to make the structures specified in this patent.

Added Materials

[0184] The strength and durability of a structure may be a function of the extruded material alone, but additional benefits may be realized by utilizing the cellular matrix as a scaffold onto which other materials are applied to fill the voids between the individual segments. Similar to a living cellular structure, the cell walls alone provide some strength, but in most cases without the internal volume filling material, the structure would not hold up. Like the water pressure in human bodies, calcification in bones, or turgor pressure in plants, the material filling the cells provides additional strength for structural support. In one aspect of the present invention, a similar method of construction utilizes material filling the cellular matrix to additionally strengthen the overall structure.

[0185] Other methods to combine materials with the cellular matrix may be used such as attachment of materials to the exterior faces or that grow into the voids of the structure.

Walls & Buildings

[0186] In a structure used as a building, one method for filling the cellular matrix may be described with reference to FIG. 31, where the internal structure 3101 of a wall 3100 includes a septum layer 3102 that separates one area of the wall from the other areas. Multiple septums 3102 may be utilized, but in this example one septum layer 3102 is used. Spray foam insulation is applied from the interior side 3112 of the wall and is stopped by the septum layer 3102 from penetrating further into the wall assembly. The spray foam 3103 fills a depth determined by reference to the R-value desired from the wall assembly 3100.

[0187] The next step is the application of concrete 3104 from the exterior side 3113 by means of a shotcrete, pumping or other appropriate application mechanism or technique. Concrete 3104 may be applied so that the entire matrix 3101 is filled with concrete 3104 and then finished or the concrete 3104 may be applied in a thickness that leaves the exterior face grid 3105 partially exposed. A stucco finish 3106 may then be applied using the outer face 3105 of the cellular matrix as lathe to which the stucco is secured. Other exterior finishes may also be utilized that are attached to the concrete 3104 and grid 3105 utilizing existing or yet to be developed construction practices and products. Once the concrete 3104 cures, it may serve as a significant structural element of the building, as is common in thin shell concrete construction. In this case, however, the cellular matrix 3101 is acting as both a form and part of the tensile reinforcement of the concrete. After sufficient curing of the concrete 3104, spray applied gypsum 3107 may be applied to the interior face 3112 of the structure, struck off with a tool, sanded smooth, and finished as is common with other interior wall finishes. Numerous other interior surface finishes may also be used.

[0188] Certain areas or portions 3108 of the cellular matrix may be extruded in a solid fashion to create decorative trim elements 3108, joints, or to help integrate other fixtures or equipment into the wall assembly. Conduit, raceways, wiring, airways, and pipes may be either printed in situ or integrated after the concrete cures. If completed after the concrete cures, spaces may be routed out in the foam 3103, and normal conduit/piping may be placed in the routed voids and then reinsulated, if desired, prior to the application of the interior finish.

[0189] One optional method to increase the strength of the structure is to apply a sprayed reinforcing material that coats the outer surfaces of the extrudate and begins to build up at joints to round out and reinforce the cellular matrix. The sprayed reinforcing material may provide a rigid sheath around the extrudate, adding strength without adding substantial weight. This reinforcement technique could be analogized to the calcification method that certain microscopic sea creatures use to build their skeletons.

[0190] The addition of materials to the cellular matrix may be accomplished with conventional normal manual processes, may be automated by utilizing the movement mechanisms described here or by any other techniques that accomplish the desired addition of materials to the matrix.

Scale and Utilization

[0191] The building construction examples described here are merely exemplary; myriad other uses are possible, including, without limitation, use in the fields of building construction, manufacturing, agriculture, automotive, aerospace, fashion, three-dimensional printing, furniture, and medicine among many others. The scale in the construction industry may be between ½″ to 6″ or greater per segment. Smaller scale segments may be as small as those produced by skipping layers on a 3D printer on the order of 0.002″. Larger scale structures may incorporate volumes and spans as great as several feet or more. The spans possible and desirable depend on material properties, extrudate section properties, and segment shape.

[0192] A small device may be built with the techniques described here. For instance, an object with hollow interior voids may be fabricated and the exterior coated with porcelain enamel to form a coffee cup. A larger scale example might be the internal wall structure of an airliner where the exterior skin is fitted over a cellular matrix with an internal space made up of insulation, an airtight pressure vessel membrane, and interior finishes.

[0193] With the robotic armature or other motion mechanisms, additional scale and motion flexibility may be gained by mounting the mechanism on a rail system that allows for a greater degree of motion. A more flexible method may be enabled by mounting a robotic arm on a mobile platform to produce a robotically controlled platform 3200 that has infinite range of motion as shown in FIG. 32.

Logic Flow

[0194] FIG. 33 is a logic flow diagram. This is a basic, exemplary overview of steps that may be taken to produce a given structure. Numerous substitutions, alterations, modifications, omissions and the like may be possible and desirable depending on the nature of the structure being fabricated and the materials being used. In the method of FIG. 33:

[0195] a. An object or structure is conceived and documented preferably with a CAD program in step 3300.

[0196] b. This design's volume is filled with a cellular matrix having desirable properties for the final structure in step 3301.

[0197] c. A sequential pathway tracing each segment of the matrix is derived in step 3302.

[0198] d. The movement mechanism is programmed with this sequential motion pathway in step 3303. Additional information relating to speeds, temperatures, stop/start, flow, and other properties may be input with the programming.

[0199] e. The program is executed, inducing motion and extrusion to create the structure in step 3304.

[0200] f. Once portions or the whole is complete, other materials may be added to the structure in step 3305.

Septum

[0201] A septum is generally defined as a layer that separates one region from another. It may be a porous layer that is embedded in a material or a solid material that prevents material penetration or a combination of both. The septum may be an extruded structure created by the same mechanism and process which creates the cellular matrix. An additional component of the extrusion mechanism may be configured to extrude or deposit a material distinct from the matrix to form a septum during the additive process. A septum may also be a material fixed to an outer surface or embedded within the cellular matrix. Beneficial characteristics of the septum may be to separate one region of the cellular matrix from another, internally reinforce a material, provide attachment means of a material to the cellular matrix similar to a lathe, or where a densification of the printed material may provide mechanical adhesion for an added material.

[0202] FIG. 34 illustrates various configurations of a cellular matrix, septum, and infill material. Cellular matrix 3101 has a septum that may be located at position A, B, or C or a combination of these example positions. Various materials may be added in regions 3401, 3402, 3403, and/or 3404. Materials may stop at, flow through, or generally be contained within these regions. The septum at position C may be adhered, thermally or ultrasonically welded, or otherwise attached to matrix 3101. Material 3404 may be added to the exterior of septum at position C. Septum C may act as internal reinforcing within a material, or may be a barrier to confine a material to a certain volume within matrix 3101. Septums A and B may similarly serve any of these functions.

[0203] Several possible embodiments are illustrated in FIG. 35. FIG. 35a illustrates a matrix 3101 with a septum at position C where material 3 is spray foam applied from exterior side 3113, expanding to a certain depth and corresponding r-value. Material 2 is concrete added from exterior side 3113 and Material 1 is a stucco with a reinforcing lathe at septum position A.

[0204] FIG. 35b shows a matrix 3101 with a septum at position C that restricts the penetration and expansion of spray foam material 2 to a specific region within matrix 3101. Material 1 is concrete where matrix 3101 acts as reinforcing within the concrete and bonds it to the other materials. The material 1 concrete extends beyond the face of matrix 3101 and forms the surface finish.

[0205] FIG. 35c illustrates a fully encapsulated matrix 3101 with a foam material 2 and a barrier material at position C. The boundary surface at septum location A may be milled to a finished surface and then material 1 may be affixed to the foam surface. Material 3 may also affixed to the outer bounds of septum C.

[0206] Figures are merely illustrative and material/septum combinations may take on many other configurations. The septum may also range from location to location within the same assembly.

[0207] One embodiment of the septum may be produced by freeform or layer-based extrusion. In this manner, the septum may be at position A, B, or C in FIG. 34 and may be extruded at the same time as the matrix, but in an appropriately dense freeform or layer-based configuration, or may be secondary material deposited along the surface of matrix 3101 at position C. The septum may be solid barrier or open lath. The septum may be an integral subsurface of varying parameters to which other added materials may bond, forming an exterior surface of a solid assembly. In this instance, the bond between septum and materials may provide the properties of a composite material.

Enclosed Septum

[0208] FIG. 36 illustrates an embodiment in which a septum fully or substantially encloses a discrete volume within Cellular Matrix 3601. Matrix 3601 may provide both the shape of the assembly as a whole and may frame the interior passageways or regions to be enclosed by a closed septum 3602. The closed septum 3602 may be a sleeve or tube of flexible material, like a sock, that may be inserted into cellular matrix 3601 and subsequently filled with material 3603, such that the filled septum expands to fill and conform to the interior volume framed by the cellular matrix. The closed septum 3602 may be any material that performs the functions listed herein and may be made of fabric, plastic, polymer, metal, cementitious, rubber, dissolvable material, sprayed material, piping, 3D printed material, or other functional materials. Added filler 3603 may be concrete, foam, sand, water, air or other materials. The closed septum 3602 may be used as reinforcing within the cellular matrix 3601 and may contribute to compressive and/or tensile load bearing capacity.

[0209] The cellular matrix 3601 may provide the rough shape when the closed septum 3602 is filled 3603. The septum and material may act as reinforcing tubes within a wall or other assembly. They may be bundled as illustrated in FIG. 36 or may be singular tubes as shown in 3604. If closed septums 3602 are bundled they may be bound with other materials, by the matrix itself, or multiple tubes may exist in one channel. Closed septums may also vary in size, cross section, and configuration to respond to forces, or create forces within an assembly.

[0210] Closed septums 3602 and filler 3603 may be located in a variety of locations within the cellular matrix 3601 to alter the properties of the composite assembly. Filler material 3603 or 3605 may add mechanical, thermal, electrical or other properties to the composite. Larger closed septums 3602 may provide a large central chamber for filler material 3603 or multiple smaller closed septums may be stacked adjacent to one another in a vertical or horizontal plane to act as a generally planar septum for the addition of other materials, or around the perimeter of a cellular matrix to provide a cavity in the middle.

[0211] A closed septum 3604 may also be filled 3605 with air, water, or dissolvable material temporarily while the remaining space within the cellular matrix 3601 is filled with other materials. The filler 3605 air or water may then be drained or dissolved to provide an open raceway for wiring or pipes or may be kept as an air or water passage.

[0212] The interior of a closed septum within a cellular matrix may be filled with a material or house a component of the assembly. The filled or occupied septum may function as any kind of load-bearing element or other conventional element of the assembly being fabricated. In architectural, infrastructure, or other construction applications, closed septums and resulting internal volumes may accommodate insulation, utility infrastructure, heating and cooling, drainage, ducts, or more recent innovations such as storage for batteries, rainwater, or filtration devices for water or air. Applications of composite cellular matrix assemblies in other industries such as aerospace or marine components may utilize internal septums and voids for storing fuel, air, water, or other resources. Electrical and mechanical systems may also utilize voids or cavities created using closed septums.

Composite

[0213] The terms ‘composite material’ or ‘composite assembly’ as they are used herein refer to a combination of materials in an integral manner which results in a product having properties superior to those of the individual materials which comprise it. The cellular matrix may serve structural and other purposes without the addition of filler materials, but increased performance and additional functionality may be achieved through the incorporation of other materials and components to form a composite material or assembly. Just as the pattern of a woven glass or carbon fiber in a resin-fiber composite may be configured for certain loading properties, so the cellular matrix may be configured to achieve certain performance criteria either as a standalone component or as a composite. As in the case of fiberglass-resin composites, superior qualities are often the result of combining products which have opposing modes of failure.

[0214] In the case of compression loading, the mode of failure of the cellular matrix may be buckling of its individual members or struts. When another material such as expanding foam is added to the matrix, surrounding each strut, it is braced along the entire length of the strut by the expanding foam. The foam prevents the strut from deflecting or buckling out of plane, thereby increasing the compressive force that may be borne by the composite assembly. Likewise, the foam is prevented from crushing by the cellular matrix. The compressive strength of either the cellular matrix or expanding foam may be less than the composite strength of the overall assembly.

[0215] The matrix may also receive materials which are themselves composites. In one such embodiment, the cellular matrix may be used as a form which is wrapped in resin-impregnated carbon fiber to form a lightweight and rigid composite airfoil or hydrofoil. The properties of this composite may be further enhanced by filling the resulting shell-matrix structure with a rigid foam. Various degrees of composite behavior may be achieved through such combinations.

[0216] Composite assemblies may be fabricated through added chemicals for chemical bonding at joints or structurally wrapping joints for tensile reinforcing. One example would be with the profiles illustrated in FIG. 45 that have a branching arm of extrudate in cross section. Added materials 4502 would fill between the arms 4501 and physically interlock the extrudate with the added material. The goal in some instances may be to increase the structural link between the two materials, in other instances a chemical may be added to the matrix to cause slippage or non-contact between two materials. Beneficial composite effects may be designed into the manner of creating a cellular matrix and the method of placing additional materials into or on the matrix.

Freeform Additive Manufacturing

[0217] Freeform additive manufacturing (FAM) departs from conventional additive manufacturing in several respects. First, rather than discretizing the volume of an object through ‘slicing’, in which the object is subdivided into generally planar layers, FAM utilizes computational meshes to generate ‘cells’ which are made up of various numbers of segments.

[0218] Second, where conventional methods deposit or fuse material in successive layers corresponding to the digital slices comprising an object, FAM utilizes freeform extrusion to deposit materials along three dimensional pathways which may vary in sequence depending upon the topology of the cell (e.g. tetrahedra, icosahedra, etc.), and along which material may be actively solidified so as to retain its three dimensional shape even where it is supported by underlying structure only at a point or node, rather than along a line or polyline. This is to say that where other methods rely upon generally laminar deposition of material, even where such deposition is not planar, FAM may deposit material along freeform pathways without substantial contact with or support from any underlying structure or material.

[0219] Freeform additive manufacturing allows material to be added to an object at any angle or orientation. In FIG. 37 an object 3711 is constructed. When constructed with a horizontal base platform 3708 region 3702 is built atop 3701. With freeform additive manufacturing region 3703 may be constructed on the side of region 3702. There may be no need for any supporting material in region 3704 as is common with typical 3D printing techniques. The movement mechanism 102 from FIG. 1 may be oriented to build up material to the side of region 3702. Additional benefits of freeform additive manufacturing may be to construct object 3711 starting from a vertical build platform 3709 or ceiling build platform 3710 or other orientation of build platform. In the case with a vertical build platform 3709, material may be added directly horizontal or vertical, without regard to gravity, layerwise buildup, or support material.

Selective Solidification

[0220] One beneficial characteristic of freeform additive manufacturing is that material may be selectively solidified almost immediately upon exit from the orifice. Material may also be built up in a laminar fashion and then switched to freeform upon changes in parameters. It may be beneficial to utilize both laminar and freeform extrusion as the need may arise. Freeform AM may also solidify material almost wholly upon exit from the aperture or may leave it partially molten to allow process speeds to increase. The degree of solidification and the location at which solidification occurs may be modulated by process parameters available within this invention.

Extrudate Shape

[0221] A nozzle orifice is shown in FIG. 38 with a shaped die 3801 and orifice in proximity to cooling channels 3802 that facilitate solidification of the extrudate. Extrudate flows out of an orifice 3801 with one embodiment shaped as shown with a plurality of arms in various directions. Cooling channels 3802 may be incorporated as shown within the nozzle and near upon exit from the nozzle same or other cooling channels are used to facilitate solidification of the extrudate upon exit from the extruder.

[0222] Various configurations of a multi-armed extrudate shape are illustrated in FIG. 39 that may include compound arms or branching lobes. A general principle in some embodiments of this invention is that surface area of the extrudate is maximized while cross sectional area is minimized in order to facilitate greater solidification. Such arms may also serve to prolong the length for which the cooling fluid flows along the extrudate member in order to better facilitate solidification of the material.

[0223] The sections shown in FIG. 39 may have cooling fluid 3802 flowing between or upon the arms of the shaped extrudate 3801. FIG. 40 illustrates a similar embodiment wherein the cooling fluid may flow within partially or fully enclosed channels within the shaped extrudate.

[0224] The heat of the nozzle assembly may keep the plastic molten through the extrusion process. The proximate location of cooling passages may interact with the extrudate internal and external to the orifice. The relationship of heating and cooling mechanisms proximate to an extrusion shape may enable freeform extrusion, solidification near upon exit from the nozzle, and selective solidification of extrudate upon exit from the nozzle. These relationships may be dynamic and controlled in a dynamic manner.

Extrudate Temperature Control

[0225] With the embodiment illustrated in FIGS. 38 and 39, the heating and cooling mechanisms are integral to the nozzle assembly and allow for freeform extrusion that solidifies near upon exit from the nozzle, selective solidification of extrudate, laminar buildup of material, and heat welding of additive joints.

[0226] FIG. 43 shows several possible configurations of a cooling system which may be integral to the nozzle assembly, and how each configuration produces selective solidification characteristics.

[0227] FIG. 43a depicts one embodiment of a nozzle 4301 having cooling fluid passages 4302 located near the extrudate 4303 within the nozzle, and which have apertures 4307 near the nozzle opening 4304 where the cooling fluid 4305 flows directly onto the extrudate. In this embodiment, the region wherein the extrudate is actively cooled 4306 includes a portion of the interior of the nozzle as well as some distance beyond the nozzle opening.

[0228] FIG. 43b depicts another embodiment of a nozzle 4301 having cooling fluid passages 4302 which may be integral to the nozzle assembly, but are not located immediately adjacent to the extrudate 4303 and nozzle opening 4304. In this embodiment, the region wherein the extrudate is actively cooled 4306 is shifted downward, does not significantly extend into the nozzle interior, and may also exclude a short distance beyond the nozzle opening. This can allow the extrudate to remain hot within the area immediately outside the nozzle opening which may facilitate heat welding at connections between members or layers of extrudate.

[0229] FIG. 43c depicts another embodiment of a nozzle which may combine configurations shown in FIGS. 43a and 43b. Multiple cooling fluid arrangements may be used independently or in combination to achieve precise control over the solidification of the extrudate. All of the cooling configurations shown in FIG. 43 may be used in combination with aspects of other nozzle embodiments disclosed herein.

[0230] FIG. 47 shows one embodiment of a Nozzle 4701 which directs a Heating Medium 4702 through an opening which may be integral to the Nozzle. The Heating Medium 4702 is directed toward the Nozzle Orifice 4703 where material exits the nozzle and forms a Joint 4704 with previously solidified material, resulting in a Heat Weld 4705 having desirable bond strength.

[0231] FIG. 41 depicts the use of an annular ring 4104 configuration through which cooling fluid 4102 may flow within the nozzle 4101 and/or onto the extrudate 4103 upon exit from the nozzle orifice 4105. The distance between the annular cooling passageway and the extrudate and nozzle orifice may vary in a similar manner to the passageways shown FIG. 43. Multiple annular passageways may also be incorporated in the nozzle design and used independently or in combination as depicted in FIG. 43.

[0232] FIG. 49 depicts a nozzle wherein internal passages within or integral to the nozzle body 4901 allow the flow 4902 of a material which serves as a bonding agent, such that the bonding agent 4902 may accumulate at a connection point 4904 within the cellular matrix. The bonding agent may be an adhesive suited to the polymer being extruded, such as an epoxy or resin, or may alternatively be a solvent suited to the polymer being extruded, such as acetone in the case of ABS.

[0233] The nozzle may be manufactured using any one or a combination of methods which include but are not limited to casting, machining, and sintering. Additive forms of these methods in particular may be used to manufacture multiple systems within a single nozzle device.

Extrusion Orientation

[0234] The shape of the extrudate may be designed such that it provides the same or comparable performance characteristics when extruded at various angles relative to the median axis of the extruder or nozzle. Performance characteristics may include but are not limited to: rate of solidification, structural properties, and integration with added materials within a composite assembly.

Co-Extrusion of Multiple Materials

[0235] FIG. 15 depicts the coaxial extrusion of a secondary polymer or polymers within or surrounding the primary polymer, having distinct material properties from the primary polymer which enhance desirable performance characteristics such as solidification for freeform extrusion, and chemical or mechanical integration of filler materials within the final extruded structure.

[0236] The nozzle orifice in FIG. 38 may also extrude additional materials within and surrounding the extruded polymer. This may include one or more fiber additives such as wood, carbon, glass, steel, potassium titanate, aramid, and other compatible fibers for additional tensile and flexural strength. Each of these fiber types may be added in chopped form or as a continuous strand.

[0237] Other additives which may be extruded within the primary polymer may be used to achieve functions such as protection from degradation by ultraviolet light, fire resistance, or resist damage from other environmental conditions. Another class of additives may be used to increase the adhesion of the polymer to itself, such as polymer chain extenders. These additives facilitate molecular cross-linking across polymer chains in order to provide better strength properties, particularly in tensile loading. These improved properties may improve the bond strength between extruded members, and also may reduce both ductile and brittle fracture as well as buckling of individual members. Chain extension may be especially useful in layer-based additive extrusion, where material is deposited upon previously extruded layers which may still be hot, facilitating the chain extension reaction between layers. The inter-layer bonds in additive extrusion are conventionally the points of failure in structural applications; therefore, the combination of a shaped extrusion profile (providing greater surface contact and mechanical bonding) and polymer chain extending compounds (providing molecular bonding between unhardened polymer layers) may significantly improve the structural properties of layer-based additive extrusion products.

[0238] FIG. 44 shows several possible arrangements of multiple polymers and additives within the cross-section of the extrudate.

[0239] FIG. 44a shows a secondary material 4401 extruded as a jacket enclosing the primary material 4402. In this instance, the secondary material 4401 may solidify or stiffen more quickly than the primary material 4402 and may thus be used to increase process speed where the primary material may offer superior structural performance. The same configuration may use the secondary material 4401 to facilitate bonding with a filler material such as cement. An enclosed jacket configuration as illustrated in FIG. 44a may be particularly desirable if the secondary material 4401 may act as a protective layer providing resistance to ultraviolet exposure, thermal expansion, impact loads, flame spread and smoke development, or other adverse conditions.

[0240] FIG. 44b shows a secondary material 4401 extruded along a portion of the perimeter of the primary material 4402. This embodiment in particular may take advantage of a secondary material 4401 which solidifies rapidly to stiffen a primary material 4402 which has desirable material properties but which hardens more slowly, such that the product may benefit from the properties of the primary material 4402 and the manufacturing process may benefit from the properties of the secondary material 4401.

[0241] FIG. 44c shows rods of secondary material 4401 embedded within the protrusions of the shaped extrudate. Such a configuration may incorporate secondary materials 4401 such as a fiber, strand, wire, or other component which may offer added tensile strength.

[0242] The configuration of the extrudate shown in FIG. 44c may also utilize a secondary material 4401 which melts at a slightly higher temperature than the primary material 4402, such that when the nozzle cooling system is active the extrudate remains solid or sufficiently rigid to support the molten primary material around it. However, when the nozzle cooling system is not active or less active, or if the temperature of the nozzle is actively raised for an appropriate period, the extrudate may melt or soften sufficiently to be broken. At such points the extruder may stop and move to a different position without the need for a device to cut the embedded secondary material, as is needed with continuous fibers or wires.

[0243] Any of the configurations shown in FIG. 44 as well as FIGS. 15 and 18 wherein secondary materials are incorporated into the extrudate may also be used to achieve additional functionality within the matrix structure, making use of fiber-optic, dielectric, electrical or thermal conductivity, and other such properties of a single or composite extrudate.

Position Detection

[0244] One such function of a secondary material is a method of marking target points such as joints or extrema within the cellular matrix. FIG. 46 depicts a nozzle 4601 which may dispense an extrudate 4604 and a marking material 4602, such as a metal powder, at a target point 4603 along an extrudate member 4604. The marking material may retain a distinct dielectric, magnetic, capacitive, or other such property which subsequently may be detected by a sensor capable of locating, storing, and monitoring the position of marked target points in three dimensional space. The sensor may be connected to the movement mechanism such changes in the location of any target point or points are communicated to the controller of the motion mechanism and extrusion system. The controllers may then adapt process parameters, motion planning, and other variables to respond to changes, repair damage, or otherwise self-correct.

Pre-Fabrication

[0245] An overall object or structure may be broken down into component parts that may be constructed separately and then joined together to make a larger assembly. Components of various sizes and configurations may be produced with this method. Components may be jointed together through various means to form a larger structure. Component jointing methods may include friction, mechanical fasteners, welding, slots, dovetails, or any other means to securely fasten one object to another. Components may be joined that have been pre-filled with other materials or may be joined together prior to the addition of other materials.

Laminar Extrusion with Shaped Extrudate

[0246] FIG. 48 illustrates methods of using a profile shaped extrudate to build up an object in a laminar configuration. As indicated in FIGS. 48a and 48b a profile shaped extrusion may add mechanical bonding between layers of extrudate. A profile shaped extrusion may increase the surface area bonding between layers and the interlayer shear resistance of an object. Additionally modulating from a profile that is appropriate for freeform additive manufacturing may also be useful for laminar buildup as illustrated in FIGS. 48c and 48d. The freeform extrusion profile shape with lobes compresses to form a flattened shape that may increase interlayer bonding and mechanical strength.

[0247] Integral nozzle cooling may also allow large parts to be constructed without regard to curling and delamination between layers. The integral cooling in the nozzle selectively solidifies the material to a point that may reduce further shrinkage and delamination.

Multi-Block Construction

[0248] FIG. 19 depicts one possible configuration of a single unit of a cellular matrix block. The unit can be printed with the faces diagonalized to add stability and strength to the overall matrix structure as well as to reduce warping. The consistent dimensioning of the overall block allows for a likewise consistent diagonalization of the units themselves.

[0249] FIG. 37 demonstrates the utility of concatenation of overall blocks. To preserve the overall geometry, block 3703 may be separated from blocks 3701 and 3702. Different concatenations of the blocks may allow the overall object to be produced.

[0250] FIG. 21 further demonstrates the utility of the concatenation of blocks. A program may diversify the application of a cellular pattern. The application of the different patterns may be facilitated by the concatenation of different blocks.

[0251] Different arrangements of the components and activities depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below.