Adaptable high-performance extrusion head for fused filament fabrication systems

Abstract

An extrusion head for a three-dimensional printer is disclosed including a feed tube, a heater, a cooler, and a bridge. The feed tube can be made of metal and has an inlet for receiving a forwardly driven filament of solid deposition material, an outlet, a downstream portion adjacent to the outlet, an upstream portion upstream from the downstream portion, and an internal passage extending from the inlet to the outlet. The heater is thermally coupled with the downstream portion of the feed tube for heating a filament to provide softened fluid deposition material. The cooler is thermally coupled with the upstream portion and spaced generally axially from the heater to define a generally axially extending gap traversed by the feed tube. The bridge traverses the gap and provides a rigid mechanical connection between the heater and the cooler.

Claims

1. An extrusion head for a three-dimensional printer, the extrusion head comprising: a generally axially extending metal feed tube having an inlet for receiving a forwardly driven filament of solid deposition material, an outlet, a downstream portion adjacent to the outlet, an upstream portion upstream from the downstream portion, and an internal passage extending from the inlet to the outlet; a heater thermally coupled with the downstream portion for heating a filament positioned within the feed tube internal passage to provide softened deposition material; a cooler thermally coupled with the upstream portion for reducing upstream heat transfer, the cooler spaced generally axially upstream from the heater; and a generally axially extending gap, bound by a bridge traversing the gap between the cooler and the heater; wherein, the gap is traversed by the metal feed tube; the bridge is spaced radially and apart from the metal feed tube, the bridge provides a rigid mechanical connection between the heater and the cooler, and the bridge at least partially reduces mechanical loading on the feed tube, wherein the bridge comprises: a first structural component, spaced radially and apart from the feed tube, and having a first portion bearing against the heater and a second portion bearing against the cooler, wherein the first structural component at least partially relieves mechanical loading on the feed tube; and a second structural component, spaced radially and apart from the feed tube, and having a first portion bearing against the heater and a second portion bearing against the cooler, wherein the second structural component at least partially relieves mechanical loading on the feed tube.

2. The extrusion head of claim 1, wherein at least one of the first structural component or the second structural component is a spacer or tension member.

3. The extrusion head of claim 1, wherein the bridge further comprises a third structural component, spaced radially and apart from the feed tube, and having a first portion bearing against the heater and a second portion bearing against the cooler, wherein the third structural component at least partially relieves mechanical loading on the feed tube.

4. The extrusion head of claim 1, wherein the metal feed tube comprises stainless steel.

5. The extrusion head of claim 4, wherein the metal feed tube comprises hypodermic tubing.

6. The extrusion head of claim 1, wherein the metal feed tube has a wall thickness less than 0.005 in. (less than 0.13 mm).

7. The extrusion head of claim 1, wherein the metal feed tube has an inside diameter from 0.07 in. to 0.13 in. (1.8 mm to 3.3 mm).

8. The extrusion head of claim 1, wherein the metal feed tube has a length from 0.5 in. to 3 in. (12 mm. to 76 mm.).

9. The extrusion head of claim 1, wherein the portion of the feed tube traversing the gap extends axially from 0.03 in. to 3 inches (0.8 mm. to 76 mm.).

10. The extrusion head of claim 1, wherein the metal feed tube internal passage is coated internally with a material reducing adhesion of the deposition material.

11. The extrusion head of claim 10, wherein the material reducing adhesion of the deposition material is electroless nickel, an electroless nickel-boron composite, tungsten disulfide, molybdenum disulfide, boron nitride, diamond-like carbon, zirconium nitride, titanium nitride, or a combination of two or more of these.

12. The extrusion head of claim 1, further comprising a bushing having an axial bore defined by a wall secured to the feed tube downstream portion, the bushing further comprising an exterior threaded surface engaged with the heater block threaded bore.

13. The extrusion head of claim 12, wherein a line drawn from the first structural component to the second structural component passes through the bushing.

14. The extrusion head of claim 1, wherein the first structural component and the second structural component of the bridge are each loaded in either compression or tension to resist the axial push-pull forces applied by the filament feed system.

15. The extrusion head of claim 1, wherein the cooler comprises a heat sink comprising heat-conductive material.

16. The extrusion head of claim 1, wherein the cooler comprises a heat sink comprising heat-conductive material and comprising an internal heat transfer passage configured to receive a cooling fluid.

17. The extrusion head of claim 1, wherein at least one structural component comprises hypodermic tubing.

18. The extrusion head of claim 17, wherein the hypodermic tubing is sized between 7 XX and 14 XX gauge, inclusive.

19. The extrusion head of claim 1, wherein at least one- structural component comprises thermal insulation material.

20. The extrusion head of claim 19, wherein the thermal insulation material is calcium silicate, ceramic, glass, an engineering thermoplastic, zirconia, mica, Portland cement or a combination of any two or more of these.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIGS. 1, 2, and 3 are perspective views of an embodiment of the extrusion head.

(2) FIG. 4 is a front elevation view of an embodiment of the extrusion head of FIGS. 1 through 3.

(3) FIG. 5 is a top plan view of an embodiment of the extrusion head of FIGS. 1 through 3.

(4) FIG. 6 is a bottom plan view of an embodiment of the extrusion head of FIGS. 1 through 3.

(5) FIG. 7 is a side elevation view of an embodiment of the extrusion head of FIGS. 1 through 3.

(6) FIG. 8 is a section view taken along section lines 8-8 of FIG. 7 of an embodiment of the extrusion head of FIGS. 1 through 3.

(7) FIG. 9 is a section view taken along section lines 9-9 of FIG. 7 of an embodiment of the extrusion head of FIGS. 1 through 3.

(8) FIGS. 10 through 12 are perspective views of an embodiment of the extrusion head.

(9) FIG. 13 is a front elevation view of an embodiment of the extrusion head of FIGS. 10 through 12.

(10) FIG. 14 is a top plan view of an embodiment of the extrusion head of FIGS. 10 through 12.

(11) FIG. 15 is a bottom plan view of an embodiment of the extrusion head of FIGS. 10 through 12.

(12) FIG. 16 is a side elevation view of an embodiment of the extrusion head of FIGS. 10 through 12.

(13) FIG. 17 is a section view taken along section lines 17-17 of FIG. 16 of an embodiment of the extrusion head of FIGS. 10 through 12.

(14) FIGS. 18 through 20 are perspective views of an embodiment of the extrusion head.

(15) FIG. 21 is a front elevation view of an embodiment of the extrusion head of FIGS. 18 through 20.

(16) FIG. 22 is a top plan view of an embodiment of the extrusion head of FIGS. 18 through 20.

(17) FIG. 23 is a bottom plan view of an embodiment of the extrusion head of FIGS. 18 through 20.

(18) FIG. 24 is a side elevation view of an embodiment of the extrusion head of FIGS. 18 through 20.

(19) FIG. 25 is a section view taken along section lines 25-25 of FIG. 24 of an embodiment of the extrusion head of FIGS. 18 through 20.

(20) FIGS. 26 through 28 are perspective views of an embodiment of the extrusion head.

(21) FIG. 29 is a front elevation view of an embodiment of the extrusion head of FIGS. 26 through 28.

(22) FIG. 30 is a top plan view of an embodiment of the extrusion head of FIGS. 26 through 28.

(23) FIG. 31 is a bottom plan view of an embodiment of the extrusion head of FIGS. 26 through 28.

(24) FIG. 32 is a side elevation view of an embodiment of the extrusion head of FIGS. 26 through 28.

(25) FIG. 33 is a section view taken along section lines 33-33 of FIG. 32 of an embodiment of the extrusion head of FIGS. 26 through 28.

(26) A list of the reference characters used in the drawings follows.

(27) TABLE-US-00001 100 Extrusion Head 101 Cooler 102 Heater 103 Nozzle 104 Feed Tube 105 Second Cooler 106 Bushing 107 Spacer 108 Tension Member 109 Inlet (of 104) 110 Filament 111 Outlet (of 104) 112 Downstream Portion (of 104) 113 Upstream Portion (of 104) 114 Internal Passage (of 104) 115 Softened Deposition Material 116 Gap 117 Bridge 118 Platform 119 Three-Dimensional Printer 120 Heating Element 121 Temperature Sensor 122 Threaded Bore (of 102) 123 External Thread (of 112) 124 Axial Bore (of 106) 125 Exterior Threaded Surface (of 106) 126 Inlet (of 122) 127 Outlet (of 122) 128 First Thermally Conductive Portion 129 Second Thermally Conductive Portion 130 Thermally Conductive Flange Portion 131 Internal Heat Transfer Passage 132 Cooling Fluid 133 Sleeve (Heat Sink) 134 First Portion (of 107) 135 Second Portion (of 107)

DETAILED DESCRIPTION OF THE DISCLOSURE

(28) FIGS. 1 to 33 show exemplary extrusion heads 100 for a three-dimensional printer or similar device 119 also including a supply of filament material 110, a part support base 118, and a mechanism, which can be conventional, for moving the extrusion head 100, the building table 118, or both relative to the other. The extrusion head 100 includes, for example, a cooler 101, a heater 102, a nozzle 103, a feed tube 104, a second cooler 105, a bushing 106, a spacer 107, and a tension member 108.

(29) The feed tube 104 in this embodiment is made of metal, and extends generally axially. The feed tube 104 has an inlet 104 for receiving a forwardly driven filament 110 of solid deposition material, an outlet 111, a downstream portion 112 adjacent to the outlet 111, an upstream portion 113 upstream from the downstream portion 112, and an internal passage 114 extending from the inlet 104 to the outlet 111.

(30) The heater 102 is thermally coupled with the downstream portion 112 for heating a filament 110 positioned within the feed tube 104 internal passage 114 to provide softened deposition material 115.

(31) The cooler 101 is thermally coupled with the upstream portion 113 for reducing upstream heat transfer. The cooler 101 is spaced generally axially upstream from the heater 102 to define a generally axially extending gap 116 traversed by the metal feed tube 104.

(32) A bridge 117 (for example, at least one spacer 107 or at least one tension member 108) is spaced radially from the metal feed tube 104, traversing the gap 116, and providing a rigid mechanical connection between the heater 102 and the cooler 101.

(33) Optionally in any embodiment, the metal feed tube 104 comprises stainless steel or zirconia, and suitably can be made from hypodermic tubing.

(34) Optionally in any embodiment, the hypodermic tubing is sized from 10×× to 14×× gauge.

(35) Optionally in any embodiment, the metal feed tube 104 has a wall thickness from 0.001 to 0.005 in. (0.025 mm to 0.13 mm), a wall thickness less than 0.005 in. (less than 0.13 mm), or from 0.001 to 0.004 in. (0.025 mm to 0.1 mm), or from 0.002 to 0.004 in. (0.05 mm to 0.1 mm).

(36) Optionally in any embodiment, the metal feed tube 104 has a wall cross-sectional area from 0.002 in.sup.2 to 0.005 in.sup.2(1 mm.sup.2 to 3 mm.sup.2), or from 0.0017 in.sup.2to 0.004 in.sup.2(1.1 to 2.6 mm.sup.2).

(37) Optionally in any embodiment, the metal feed tube 104 has an inside diameter from 0.07 in. to 0.13 in. (1.8 mm to 3.3 mm), or from 0.07 in. to 0.11 in. (1.8 mm to 2.8 mm).

(38) Optionally in any embodiment, the metal feed tube 104 has a length from 0.5 in. to 3 in. (12 mm. to 76 mm.). Optionally in any embodiment, the portion of the feed tube 104 traversing the gap 116 extends axially from 0.03 in. to 3 inches (0.8 mm. to 76 mm.).

(39) Optionally in any embodiment, the metal feed tube 104 internal passage 114 is coated internally with a material reducing adhesion of the deposition material, for example, electroless nickel, an electroless nickel-boron composite, tungsten disulfide, molybdenum disulfide, boron nitride, diamond-like carbon, zirconium nitride, titanium nitride, or a combination of two or more of these.

(40) Optionally in any embodiment, the heater 102 comprises a heater block comprising thermally conductive material, at least one heating element 120, and at least one temperature sensor 121 attached to and in thermal contact with the heater block 102. Optionally in any embodiment, the heater block has an axial length from 0.2 inches to 1.5 inch (5 mm. to 38 mm.). The heater block can have a threaded bore 122.

(41) Optionally in any embodiment, the feed tube 104 downstream portion 112 has an external thread 123, and the heater block 102 threaded bore 122 and the feed tube 104 external thread 123 are engaged to thermally couple the heater block 102 with the downstream portion 112 of the feed tube 104. Alternatively, the extrusion head 100 of claim 20 includes a bushing 106 having an axial bore 124 defined by a wall secured to the feed tube 104 downstream portion 112, the bushing 106 further comprising an exterior threaded surface 125 engaged with the heater block 102 threaded bore 122. Optionally, the heater block 102 threaded bore 122 extends from an inlet 126 communicating with the feed tube downstream portion to an outlet 127.

(42) Optionally in any embodiment, the extrusion head 100 includes a nozzle 103 secured to the heater block 102 threaded bore 122 and communicating with the outlet 127 of the heater block 102 threaded bore 122.

(43) Optionally in any embodiment, the cooler 101 comprises a thermoelectric cooler or a heat sink comprising heat-conductive material. Optionally in any embodiment, the heat sink has at least a first thermally conductive portion 128 thermally coupled with the upstream portion 113 of the feed tube 104 and a second thermally conductive portion 129 generally radially spaced from the upstream portion 113 of the feed tube 104. Optionally in any embodiment, the heat sink has a thermally conductive flange portion 130 extending generally axially from the second thermally conductive portion 129 and parallel to and radially spaced from the feed tube 104. Optionally in any embodiment, the heat sink has at least first and second thermally conductive flange portions 130, each extending generally axially from the second thermally conductive portion 129, parallel to and radially spaced from the feed tube 104, and the first thermally conductive flange portion 130 circumferentially spaced from the second thermally conductive flange portion 130.

(44) Optionally in any embodiment, the heat sink comprises an internal heat transfer passage 131 configured to receive a cooling fluid 132.

(45) Optionally in any embodiment, the heat sink comprises a bore in thermal contact with the feed tube 104 along at least a portion of the gap 116.

(46) Optionally in any embodiment, the bridge 117 comprises a generally axially extending spacer 107, spaced radially from the feed tube 104. Optionally in any embodiment, the spacer 107 has at least a first portion 134 bearing against the heater 102 and a second portion 135 bearing against the cooler 101. Optionally in any embodiment, the bridge 117 comprises first and second generally axially extending spacers 107, each spaced radially from the feed tube 104, each having at least a first portion 134 bearing against the heater 102 and a second portion 135 bearing against the cooler 101. Optionally in any embodiment, the extrusion head 100 has a third generally axially extending spacer 107, spaced radially from the feed tube 104, and having at least a first portion 134 bearing against the heater 102 and a second portion 135 bearing against the cooler 101. Optionally in any embodiment, the extrusion head 100 has a fourth generally axially extending spacer 107, spaced radially from the feed tube 104, and having at least a first portion 134 bearing against the heater 102 and a second portion 135 bearing against the cooler 101.

(47) Optionally in any embodiment, the spacer 107 at least partially reduces mechanical loading on the feed tube 104.

(48) Optionally in any embodiment, the spacer 107 comprises stainless steel, zirconia, or a combination of stainless steel and zirconia, for example hypodermic tubing. Examplary suitable hypodermic tubing is sized between 7 XX and 14 XX gauge, inclusive, for example, 7 XX, 8 XXX, 8 XX, 9 XXX, 9 XX, 10 XX, 11 XX, 12XX, 13 XX, 14 XX, or a combination of two or more of these. Optionally in any embodiment, the spacer 107 comprises thermal insulation material, for example, calcium silicate, ceramic, glass, an engineering thermoplastic, zirconia, mica, Portland cement or a combination of any two or more of these.

(49) Optionally in any embodiment, the extrusion head 100 further comprises at least a first tension member 108 spaced radially from the feed tube 104 and connected to and exerting tension between the heater 102 and the cooler 101. Optionally second, third, or fourth tension members 108 can be provided.

(50) Optionally in any embodiment, the total cross-sectional area of the tension members 108 and spacers 107 is less than 0.01 square inches (6.4 mm..sup.2). Optionally, the sum of the contact areas of the tension members and spacers with the heater is between 0.005 in..sup.2 and 0.02 in..sup.2(0.25 mm..sup.2 and 3.2 mm. 2) and with the cooler is between 0.005 in..sup.2 and 0.02 in..sup.2 (0.25 mm..sup.2 and 3.2 mm.2).

(51) The inventor contemplates two design tradeoffs inherent in existing all-metal extrusion head designs:

(52) First, the heat break's thermal isolation performance is proportional to the length of and inversely proportional to the wall thickness of the thin-walled section. Poor thermal isolation results in filament softening prematurely and reduction in print quality alluded to in the '124 patent. The requirement for the heat break to carry a mechanical load is therefore at odds with its performance. The extrusion head designer must select the heat break's wall thickness to withstand reasonable incidental loads caused by machine crashes, failed prints, or human mishandling. In this manner the structural requirement put on the heat break hinders performance of the extrusion head, which in turn hinders the overall performance of the FFF machine.

(53) Second, the hot end designer may lengthen the hot zone and select a nozzle of large bore diameter to maximize potential speed of printing, or he may shorten the hot zone and select a small-bore nozzle to maximize printing resolution. Additionally, some extrusion head designs allow users to affect the length of the hot zone by swapping or adding components. Example products: E3D V6-to-Volcano conversion kits, DisTech Prometheus V2. In all such products the overall length of the extrusion head changes when the user affects the hot zone's length, which is an undesirable side effect. A change in overall length of the extrusion head requires the user to calibrate the machine's recorded offset from nozzle to print bed. Failure to perform said calibration results in a failed print or the nozzle crashing into the print bed.

(54) Existing all-metal extrusion heads borrow many design features from the '124 patent, and they all utilize a component known as a heat break to thermally isolate the heater block from cold components. The heat break typically:

(55) a. Consists of a cannulated threaded rod with two threaded sections separated by a thin-walled section several millimeters in length,

(56) b. Features a thin-walled section with inner diameter and wall thickness typically in the range specified by the '124 patent for the thin-walled tube,

(57) c. Is made of stainless steel,

(58) d. Connects to a finned heatsink or a liquid cooling system, and

(59) e. Is the only component connecting the heater block to cold components. I.e. the heat break not only functions as a thermal isolator but also as the mechanical structure carrying the heater block.

(60) In the present improved extrusion head for FFF systems, the liquefier component can be formed of a single piece of thin-wall tubing pressed, brazed, or welded to a bushing of varying length. The thin-walled tube acts as both the hot zone and the cold zone of the liquefier. The inlet of the thin-walled tube slip-fits into a hole in the cold section. The thin-walled tube can be swagged, brazed or welded to a bushing in thermal contact with the heating block. The inlet of a removable nozzle can seal with the outlet of the bushing. The heating block and bushing are made of heat conductive materials, such as aluminum alloys or copper alloys, preferably a chromium copper alloy due to its combination of thermal conductivity and high strength at the highest temperature ranges commonly encountered in FFF applications.

(61) Unlike other all-metal hot ends, the thin-walled tube does not need to be a structural member. Nor does the tube need to cantilever from an externally supported heater block as described in the '124 patent. Since it optionally can be partially or completely relieved of mechanical loading, the wall thickness of the tube can be greatly reduced to improve its thermal isolation performance. The tube's wall thickness is in the range of 0.001 to 0.005 inches. The tube thickness used in prototypes has been 0.003 inches, in the form of commercially available 14×× gauge hypodermic tubing made of stainless steel. Such a drastic reduction in the heat break's wall thickness optionally removes the need for a finned heatsink component or liquid cooling system and reduces the fan size needed to keep the cold zone cool. The overall length and girth of the extrusion head may be reduced, conserving valuable space in a typically crowded area of the FFF system, and the overall mass may be reduced.

(62) Bushings of varying length may be user-installed to effectively shorten or lengthen the hot zone, to affect the speed/resolution trade off described above. In arrangement employed in the present invention, the bushing extends upward in the direction of the cold zone rather than down below the heater block. In this manner, bushings of various lengths may be used without affecting the overall length of the hot end, preserving the recorded offset to the print bed, and preventing the need for the user to recalibrate the machine after making adjustments.

(63) The heater block optionally connects to cold zone components via two to four standoffs and zero to four screws. Optionally, three screws with three standoffs or the preferable two screws with four standoffs can be used. The standoffs are preferably made of thin-walled tubes or small-diameter rods, and the screws are of small cross-sectional area. The standoffs may be constructed off blocks of rigid insulation materials such as calcium silicate based materials. Preferably the standoffs and screws incorporate materials with a high ratio of strength to thermal conductivity, such as stainless steel or zirconia. The structural components connecting the cold and hot zones are loaded only in compression (standoffs) and tension (screws) to resist the rapidly-changing axial push-pull forces applied by the filament feed system. Components between hot and cold zones are not loaded in bending, providing maximum axial rigidity for a given axial cross-sectional area of the standoff components. The total cross-sectional area of the standoff structure optionally is minimized to minimize the heat flowing from the heater block to cold zone components. For all prototypes of the present invention, this cross-section was less than 0.01 square inches in area and the structure consisted of stainless steel screws and tubular standoffs.

(64) Optionally, the cold section is composed of a hollow heatsink component of a basically square outer shape, with inward-facing slits for heat dissipation by convection. This component's nominal wall thickness excluding the slits is roughly one fifth the overall width of the square hollow component, and this component is made of aluminum alloy. Above this component an adapter is attached to guide the filament from the feed system into the thin-walled feed tube. The ideal geometry for this adapter is specific to the FFF system. Use of an adapter allows the extrusion head to be installed on a wide variety of makes and models of FFF systems. Since the adapter is located at the coldest region of the extrusion head, it need not be made of metal. Users are free to design and make their own adapters via FFF or any manufacturing method convenient to them.

(65) Optionally, commercially available stainless steel hypodermic tubing is used for the standoffs. Four of these standoffs lightly press into mating counter bores in the cold section and in the heater block. A pair of M1.4×0.3 screws pulls the heater block toward the cold section, establishing the compressive forces in the standoffs. The tube optionally is pressed into the bushing, which optionally threads into the heater block.

(66) Optionally, a heatsink is pressed onto the thin-walled tube. Performance is not noticeably affected by omission of this heatsink.

(67) Optionally, the heater block is made of chromium copper (aka C182) and is coated with Cerakote Glacier Series ceramic coating. The coating reduces heat lost via convection and radiation. Electroless nickel plating would also work well due to its low thermal emissivity.