Filament heating in 3D printing systems

Abstract

A method of heating thermoplastic filament in additive manufacturing systems, such as 3D printing systems. In accordance with the illustrative embodiment of the present invention, the temporal rate $\frac{\mathrm{dE}}{\mathrm{dt}}$
at which heat dE is added to a portion of a segment of filament is a function of the temporal rate $\frac{dm}{\mathrm{dt}}$
at which the mass dm of the portion of the segment of filament is deposited. In particular, the temporal rate $\frac{\mathrm{dE}}{\mathrm{dt}}$
at which heat dE is added to a portion of a segment of filament is a non-linear function of the temporal rate $\frac{dm}{\mathrm{dt}}.$

Claims

1. A method comprising: depositing a portion of a segment of thermoplastic filament having a mass dm at a temporal rate $\frac{dm}{\mathrm{dt}};$ and adding heat dE to the portion of the segment of thermoplastic filament at a temporal rate $\frac{dE}{\mathrm{dt}}$ that is a non-linear function of the temporal rate $\frac{dm}{\mathrm{dt}}$ and equal to: $\frac{dE}{\mathrm{dt}}={a_n\left(\frac{dm}{\mathrm{dt}}\right)}^n+{a_{n-1}\left(\frac{dm}{dt}\right)}^{n-1}+\mathrm{.Math.}+a_1\left(\frac{dm}{\mathrm{dt}}\right)+a_0;$ wherein n is a positive integer greater than 1, a.sub.0, a.sub.1, . . . , a.sub.n-1, a.sub.n are real numbers for all n, and a.sub.n0.

2. The method of claim 1 wherein n=2.

3. The method of claim 1 wherein n=3.

4. The method of claim 1 wherein n=4.

5. The method of claim 1 wherein the segment of thermoplastic filament comprises a carbon fiber.

6. The method of claim 1 wherein the segment of thermoplastic filament comprises a metal strand.

7. The method of claim 1 wherein adding heat dE comprises exposing the portion of the segment of thermoplastic filament to a laser.

8. A method comprising: depositing a portion of a segment of thermoplastic filament having a mass m at a temporal rate $\frac{m}{t};$ and adding heat E to the portion of the segment of thermoplastic filament at a temporal rate $\frac{E}{t}$ that is a non-linear function of the temporal rate $\frac{m}{t}$ and equal to: $\frac{E}{t}={a_n\left(\frac{m}{t}\right)}^n+{a_{n-1}\left(\frac{m}{t}\right)}^{n-1}+\mathrm{.Math.}+a_1\left(\frac{m}{t}\right)+a_0;$ wherein n is a positive integer greater than 1, a.sub.0, a.sub.1, . . . , a.sub.n-1, a.sub.n are real numbers for all n, a.sub.n0, and t50 milliseconds.

9. The method of claim 8 wherein n=2.

10. The method of claim 8 wherein n=3.

11. The method of claim 8 wherein n=4.

12. The method of claim 8 wherein the segment of thermoplastic filament comprises a carbon fiber.

13. The method of claim 8 wherein the segment of thermoplastic filament comprises a metal strand.

14. The method of claim 8 wherein adding heat E comprises exposing the portion of the segment of thermoplastic filament to a laser.

15. A method comprising: depositing a portion of a segment of thermoplastic filament having a mass dm at a temporal rate $\frac{dm}{\mathrm{dt}};$ and adding heat dE to the portion of the segment of thermoplastic filament at a temporal rate $\frac{\mathrm{dE}}{\mathrm{dt}}$ that is a non-linear function of the temporal rate $\frac{dm}{\mathrm{dt}}$ and equal to at least a second-order polynomial function of the temporal rate $\frac{dm}{\mathrm{dt}};$ wherein the segment of thermoplastic filament comprises a carbon fiber.

16. The method of claim 15 wherein adding heat dE comprises exposing the portion of the segment of thermoplastic filament to a laser.

17. The method of claim 15 wherein the second-order polynomial function comprises coefficients whose values depend on material properties of the thermoplastic filament.

18. The method of claim 1 wherein a.sub.0, a.sub.1, . . . , a.sub.n-1, a.sub.n have values that depend on material properties of the thermoplastic filament.

19. The method of claim 8 wherein a.sub.0, a.sub.1, . . . , a.sub.n-1, a.sub.n have values that depend on material properties of the thermoplastic filament.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts an illustration of the salient components of additive manufacturing system 100 in accordance with the illustrative embodiment of the present invention.

(2) FIG. 2 depicts an illustration of the salient components of additive manufacturing system 100 that heat and deposition thermoplastic filament in accordance with the illustrative embodiment of the present invention.

(3) FIG. 3 depicts a flowchart of the salient tasks performed by the illustrative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(4) FIG. 1 depicts an illustration of the salient components of additive manufacturing system 100 in accordance with the illustrative embodiment of the present invention. Additive manufacturing system 100 comprises: CAD/CAM system 101, build chamber 102, turn-table 110, deposition build plate 111, robotic arm 121 (which itself comprises deposition head 122 and roller 123), thermoplastic filament spool 130, and thermoplastic filament 131. The purpose of manufacturing system 100 is to manufacture object 151.

(5) CAM controller 101 comprises the hardware and software necessary to direct build chamber 102, control robotic arm 121, deposition head 122 (including laser 204, which is shown in FIG. 2), roller 123, and turntable 110 to manufacture object 151. It will be clear to those skilled in the art, after reading this disclosure, how to make and use CAM controller 101.

(6) Build chamber 102 is a thermally-insulated, temperature-controlled environment in which object 151 is manufactured. It will be clear to those skilled in art how to make and use build chamber 102.

(7) Turn-table 110 comprises a stepper motor under the control of CAM controller 101 that is capable of rotating build plate 111 (and, consequently object 151) around the Z-axis. In particular, turn-table 110 is capable of: i. rotating build plate 111 clockwise around the Z-axis from any angle to any angle, and ii. rotating build plate 111 counter-clockwise around the Z-axis from any angle to any angle, and iii. rotating build plate 111 at any rate, and iv. maintaining (statically) the position of build plate 111 at any angle.

(8) It will be clear to those skilled in the art how to make and use turn-table 110.

(9) Build plate 111 comprises hardware on which object 151 is manufactured. It will be clear to those skilled in the art how to make and use build plate 111.

(10) Robotic arm 121 is a seven-axis arm capable of placing roller 123 at any location in the build volume of object 151 and from any approach angle. Furthermore, robotic arm can move roller 123 in: i. the +X direction, ii. the X direction, iii. the +Y direction, iv. the Y direction, v. the +Z direction, vi. the Z direction, and vii. any combination of i, ii, iii, iv, v, and vi
while rotating the approach angle of roller 123 around any point or temporal series of points. It will be clear to those skilled in the art how to make and use robotic arm 121.

(11) Deposition head 122 is hardware that heats and deposits filament 131 (which may partially or wholly contain one or more fiber strands) via roller 123.

(12) Thermoplastic filament 131 comprises chopped carbon fiber, but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which thermoplastic filament 131 has a different fiber composition as described in U.S. patent application Ser. No. 14/184,010, which is incorporated by reference.

(13) In accordance with the illustrative embodiment, filament 131 comprises a cylindrical towpreg of continuous 12K carbon fiber impregnated with thermoplastic resin.

(14) It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which filament 131 comprises chopped fibers. It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which filament 131 comprises a different number of fibers (e.g., 1K, 3K, 6K, 24K, etc.). It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the fibers in filament 131 are made of a different material (e.g., fiberglass, aramid, carbon nanotubes, etc.).

(15) In accordance with the illustrative embodiment, the thermoplastic is, in general, a semi-crystalline polymer and, in particular, the polyaryletherketone (PAEK) known as polyetherketone (PEK). In accordance with some alternative embodiments of the present invention, the semi-crystalline material is the polyaryletherketone (PAEK), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetheretherketoneketone (PEEKK), or polyetherketoneetherketoneketone (PEKEKK).

(16) In accordance with some alternative embodiments of the present invention, the semi-crystalline polymer is not a polyaryletherketone (PAEK) but another semi-crystalline thermoplastic (e.g., polyamide (PA), polybutylene terephthalate (PBT), poly(p-phenylene sulfide) (PPS), etc.) or a mixture of a semi-crystalline polymer and an amorphous polymer.

(17) When the filament comprises a blend of an amorphous polymer with a semi-crystalline polymer, the semi-crystalline polymer can one of the aforementioned materials and the amorphous polymer can be a polyarylsulfone, such as polysulfone (PSU), polyethersulfone (PESU), polyphenylsulfone (PPSU), polyethersulfone (PES), or polyetherimide (PEI). In some additional embodiments, the amorphous polymer can be, for example and without limitation, polyphenylene oxides (PPOs), acrylonitrile butadiene styrene (ABS), methyl methacrylate acrylonitrile butadiene styrene copolymer (ABSi), polystyrene (PS), or polycarbonate (PC).

(18) When the filament comprises a blend of an amorphous polymer with a semi-crystalline polymer, the weight ratio of semi-crystalline material to amorphous material can be in the range of about 50:50 to about 95:05, inclusive, or about 50:50 to about 90:10, inclusive. Preferably, the weight ratio of semi-crystalline material to amorphous material in the blend is between 60:40 and 80:20, inclusive. The ratio selected for any particular application may vary primarily as a function of the materials used and the properties desired for the printed object.

(19) In some alternative embodiment of the present invention, the filament comprises a metal. For example, and without limitation, the filament can be a wire comprising stainless steel, inconel (nickel/chrome), titanium, aluminum, cobalt chrome, copper, bronze, iron, precious metals (e.g., platinum, gold, silver, etc.).

(20) FIG. 2 depicts a schematic representation of the spatial relationship of the salient components of deposition head 122 to a segment of thermoplastic filament 131, a previously-deposited segment of that heat and deposit segments of thermoplastic filament 131. In accordance with the illustrative embodiment, the salient components of deposition head 122 comprises: roller 201, roller axle 202, filament guide 203, laser 204, and roller guide 212.

(21) In accordance with the illustrative embodiment, roller 201, roller axle 202, filament guide 203, laser 204, and roller guide 212 are held in relative position by a support structure that is not shown in FIG. 2. Furthermore, in accordance with the illustrative embodiment, the relative spatial position of roller 201, roller axle 202, filament guide 203, laser 204, and roller guide 212 are invariant, but it will be clear to those skilled in the art, after reading this disclosure, in which the relative spatial position of them is not invariant.

(22) Roller 201 is a metal wheel with roller bearings on roller axle 202 that is positioned by roller guide 212. In accordance with the illustrative embodiment, roller 201 rotates freely on roller axle 202 and presses filament 131 into previously-deposited filament 151. Filament 131 is pressed into previously-deposited filament 151 to facilitate adhesion and eliminate voids.

(23) Roller axle 202 is metal around which roller 201 rotates freely. It will be clear to those skilled in the art how to make and use roller axle 202.

(24) Filament guide 203 guides filament 131 into position so that roller 201 can press it into previously-deposited filament 151. Filament guide 203 guides filament 131 both laterally and vertically. At least a portion of filament guide 203 is transparentor substantially transparentto the light from laser 204 so that laser 204 can add heat to filament 131 while filament 131 is within filament guide 203. The details of filament guide 203 are taught in co-pending U.S. patent application Ser. No. 15/827,721, entitled Filament Guide, filed on Nov. 30, 2017, which is incorporated by reference for the purposes of disclosing how it is made and used in conjunction with the deposition of heated filaments of thermoplastic.

(25) Laser 204 is a Laserline LDM-800 diode laser that heats both a portion of a segment of filament 131 and a portion of a segment of previously-deposited filament 151 under the control of CAM controller 101. It will be clear to those skilled in the art, after reading this disclosure, how to make alternative embodiments of the present invention that use a different laser.

(26) In accordance with the illustrative embodiment, the amount of heat added to the portion of the segment of filament 131 and the portion of the segment of previously-deposited filament 151 can be instantaneouslyor at least very quicklymoderated by CAM controller 101, and it is well-known to those skilled in the art how to control laser 204 to moderate rate

(27) $\frac{\mathrm{dE}}{\mathrm{dt}}$
at which heat dE is added to the portion of the segment of filament 131.

(28) In particular, and in accordance with the illustrative embodiment of the present invention, the temporal rate

(29) $\frac{\mathrm{dE}}{\mathrm{dt}}$
at which heat dE is added to the portion of the segment of filament 131 is a function of the temporal rate

(30) $\frac{dm}{\mathrm{dt}}$
at which the mass dm of the portion of the segment of filament 131 is deposited:

(31) $\begin{array}{cc}\frac{\mathrm{dE}}{\mathrm{dt}}=f\left(\frac{dm}{\mathrm{dt}}\right)& \left(\mathrm{Eq}.1a\right)\end{array}$
or

(32) $\begin{array}{cc}\frac{E}{t}=f\left(\frac{m}{t}\right)& \left(\mathrm{Eq}.1b\right)\end{array}$
for short time intervals in discrete-time systems (e.g., t10 milliseconds, t5 milliseconds, t2.5 milliseconds, etc.).

(33) CAM controller 101 does not directly measure the temporal rate

(34) 0$\frac{dm}{\mathrm{dt}}$
at which the mass of the portion of the segment of filament 131 is deposited. Instead, CAM controller 101 uses the measurement of a proxythe linear temporal rate

(35) $\frac{dL}{\mathrm{dt}}$
at which filament is deposited as measured by the relative motion of deposition head 122 relative to build surface 111as indicative of the temporal rate

(36) $\frac{dm}{\mathrm{dt}}$
at which the mass of the portion of the segment of filament is deposited. This is reasonable becausein accordance with the illustrative embodimentfilament 131 has a uniform mass per linear L meter of filament, and, therefore, the linear temporal rate

(37) $\frac{dL}{\mathrm{dt}}$
at which filament is deposited is proportional to the temporal rate

(38) $\frac{dm}{\mathrm{dt}}\text{:}$

(39) $\begin{array}{cc}\frac{dL}{\mathrm{dt}}\frac{dm}{\mathrm{dt}}& \left(\mathrm{Eq}.4\right)\end{array}$

(40) In accordance with the illustrative embodiment of the present invention, the temporal rate

(41) $\frac{\mathrm{dE}}{\mathrm{dt}}$
at which the heat is added to the filament is a second-order polynomial function of the temporal rate

(42) $\frac{dm}{\mathrm{dt}}$
at which the mass of the filament is deposited:

(43) $\begin{array}{cc}\frac{dE}{\mathrm{dt}}={a_2\left(\frac{dm}{\mathrm{dt}}\right)}^2+a_1\left(\frac{dm}{\mathrm{dt}}\right)+a_0& \left(\mathrm{Eq}.3a\right)\end{array}$
or

(44) $\begin{array}{cc}\frac{E}{t}={a_2\left(\frac{m}{t}\right)}^2+a_1\left(\frac{m}{t}\right)+a_0& \left(\mathrm{Eq}.3b\right)\end{array}$
wherein a.sub.0, a.sub.1, and a.sub.2 are real numbers and a.sub.20, and t50 milliseconds.

(45) The values of the coefficients a.sub.0, a.sub.1, and a.sub.2 depend on the material properties of the filament, the properties of the heat source (e.g., hot gas, laser, induction, microwave, etc.), the temperature of the filament before heat is applied, the ambient temperature, the temperature of the object to which the filament is being deposited, the temporal rate at which the temperature of the filament increases with the temporal rate at which heat energy is absorbed by the filament, the temporal rate at which the temperature of the filament cools, and other process parameters. Although the values of the coefficients can be determined theoretically, in accordance with the illustrative embodiment of the present invention, they are determined empirically through trial and error.

(46) FIG. 3 depicts a flowchart of the operation of the illustrative embodiment of the present invention. In accordance with the illustrative embodiment, tasks 301, 302, 303, and 304 are all performs concurrently, albeit on successive portions of a segment of filament 131.

(47) At task 301, deposition head 122 deposits a portion of a segment of filament 131. The portion of the segment of filament 131 has a mass dm.

(48) At task 302, laser 204 adds heat dE to a portion of a segment of filament 131 as described above while a previously-heated portion of the segment of filament 131 is being pressed into position by roller 201.

(49) At task 303, deposition head 122 moves roller 201, filament guide 203, and laser 204 at the linear temporal rate

(50) 0$\frac{dL}{\mathrm{dt}}$
at which a portion of the segment of filament 131 is deposited and pressed under roller 201.

(51) At task 304, roller 201 presses a previously-heated portion of the segment of filament 131 into a previously-deposited filament 151.

DEFINITIONS

(52) For the purposes of this specification, the term filament is defined as a slender threadlike object thermoplastic that might or might not comprise a non-thermoplastic reinforcing material (e.g., a fiber, metal, etc.). It should be noted that there is no particular length associated with the term filament.

(53) It is to be understood that the disclosure describes a few embodiments and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims.