Three dimensional printer and cartridge

In one aspect of the present invention, a cartridge for use in a three dimensional (3-D) printer is described. Another aspect of the invention relates to a 3-D printer that is arranged to engage the cartridge. Various embodiments relate to devices, methods, software and systems related to the above cartridge and/or printer.

FIELD OF THE INVENTION

The present invention relates to three dimensional printing. Various embodiments of the present invention relate to particular cartridge and printer designs.

BACKGROUND OF THE INVENTION

Three dimensional (3-D) printing is an increasingly popular way of creating objects. Generally, three-dimensional printing involves dispensing successive layers of a deposition material (e.g., plastic) to form an object. In the past, manufacturing companies would use expensive, complicated equipment to print objects. However, the devices used for 3-D printing have become more affordable and simpler to use. As a result, many hobbyists and non-engineers have embraced three-dimensional printing and used it to create a wide variety of objects, such as toys, household items and even simple machines.

In various implementations, 3-D printing is performed using a computer, deposition material (e.g., plastic filament) and a printer. At the computer, a user executes a program for modeling a desired object. Data indicating the shape and features of the object is transmitted to the printer. Based on the received data, the printer determines how different parts of the printer (nozzle, platform, etc.) should be moved to form the object. The printer heats the deposition material and feeds it into the nozzle. The nozzle of the printer then releases the deposition material over the platform. The printer moves the nozzle and platform relative to one another such that the desired object is gradually formed through the deposition of successive layers over the platform.

SUMMARY OF THE INVENTION

The present invention relates to systems, methods, software, devices and hardware relating to three dimensional printing. Some embodiments of the present invention relate to a cartridge and a three dimensional printer arranged to interface with the cartridge.

In one aspect of the present invention, a three dimensional printing cartridge is described. The cartridge includes a housing, a storage compartment and a nozzle assembly. The storage compartment is positioned in the housing and is arranged to store deposition material. The nozzle assembly is positioned at least partially within the housing and is arranged to receive the deposition material from the storage compartment. The nozzle assembly also includes a heater receiving element and a nozzle. The heater receiving element is arranged to engage a heating element from an external three-dimensional printer. The heater receiving element is arranged to help heat a portion of the deposition material in the nozzle assembly. The nozzle is coupled with the heater receiving element and is fixedly attached with the housing.

In another aspect of the present invention, a three-dimensional printer is described. The printer includes a housing, a compartment, a platform, a cartridge interface and a heating element. The compartment is positioned within the housing. The platform is positioned in the compartment and is arranged to receive deposition material that is dispensed within the compartment. The cartridge interface is situated at the housing and is arranged to engage a cartridge that includes the deposition material and a nozzle assembly. The heating element is arranged to engage with the cartridge and help heat the deposition material in the cartridge. The printer is arranged to dispense the deposition material from the nozzle assembly of the cartridge over the platform. The printer is also arranged to not move the nozzle assembly while the deposition material is being dispensed.

In another aspect of the present invention, a three-dimensional printer is described. The printer includes a housing, a compartment, a cartridge interface, a platform and a contact. The compartment is positioned within the housing. The cartridge interface is situated at the housing and is arranged to engage a cartridge that includes deposition material and a nozzle assembly. The platform is positioned within the compartment and is arranged to receive the deposition material from the nozzle assembly. The contact is positioned on the platform and is arranged to send a signal indicating that the nozzle assembly has touched the contact. The printer is arranged to determine the position of the nozzle assembly over the platform based at least in part on the signal.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As noted in the Background, over time three-dimensional printers have become smaller and more affordable. As a result, they have started to spread from industrial facilities and businesses into the homes and garages of hobbyists and non-engineers.

Although the operation of three-dimensional printers has become somewhat simplified over the years, they are nevertheless still challenging to use. For example, many conventional printers require that a user manually mount a spool of plastic filament into the printer. Afterward, the user holds one end of the filament and inserts it into a feed mechanism that leads to a nozzle. When the printer is operating properly, it will continuously move the filament through the feed mechanism, melt the filament into a plastic state, and then release the plastic from the nozzle to form a desired object.

In this process, however, a number of problems can occur. For instance, the insertion of the filament into the tube and nozzle acquires fine precision and can be done improperly. It takes time and can be tedious to perform. Also, since the filament is manually handled and is exposed to the air, oil, hair and dust can easily collect on the filament and/or enter the feed mechanism. As a result, a clog can form in the feed mechanism, which can cause an error in the printing process. Whenever this happens, the user must remove the clog and realign the filament with the feed mechanism. This can be a challenging and frustrating process, particularly for a layperson.

Another source of frustration is the positioning of the nozzle prior to printing. For example, in some Cartesian printers, the printer causes the nozzle to touch the platform. In various implementations, the nozzle must touch the platform in multiple locations e.g., four or more locations. This is because in such printers, if the entire platform is not extremely flat, the print may fail. That is, the printer uses the contact between the nozzle and the platform to confirm the flatness of the platform as well as the position of the nozzle relative to the platform. In some designs, if the platform is not found to be sufficiently flat for printing, the printer will display a warning to the user. The user must then manually adjust the position of the platform. Sometimes, the user will receive multiple warnings and will have to manually adjust the position of the platform multiple times, because even a slight slant in the platform can cause printing to fail. Such a situation, of course, can cause much frustration for the user.

Various embodiments of the present invention address one or more of the above issues. Referring initially toFIG. 1, a system99for three-dimensional printing according to a particular embodiment of the present invention will be described. The system includes a printer cartridge100, a three-dimensional printer105and a computing device115.

The computing device115is arranged to transmit data indicating the dimensions and/or characteristics of an object that will be formed in the 3-D printer105. In some embodiments, for example, the computing device115stores a three-dimensional model of the object. The user may interact with the computing device to edit or create the model, and/or it may be downloaded or transferred into the computing device115. In various implementations, software on the computing device115then slices the model into multiple, successive layers. The computing device115transmits data indicating the object characteristics, layers and/or the model to the 3-D printer over a network120. Any suitable software may be installed and used on the computing device115to perform the above operations e.g., 3-D modeling software, software suitable for generating STL files, etc.

The computing device115may be any device suitable for communicating with and controlling the 3-D printer105. In some embodiments, the computing device is a laptop, a computer tablet, smart phone, desktop computer and/or another type of computing device. Any suitable network or communications protocol may be used to transmit data to and/or receive data from the 3-D printer e.g., WiFi, Ethernet, Bluetooth, etc. The network120may be wired or wireless.

The cartridge110is arranged to provide deposition material to the 3-D printer105. The cartridge110may have of wide variety of configurations, shapes and designs. (An example design of the cartridge110will be described in more detail later in this application in connection withFIG. 2A.) In some implementations, for example, a spool of filament is rotatably mounted within a housing. A feed mechanism within the housing helps direct filament towards a nozzle assembly in the cartridge. The nozzle assembly is arranged to dispense the deposition material within a compartment of the 3-D printer.

Generally, the cartridge100includes an engagement element on its exterior. For example, the engagement element may be but is not limited to a slot, a latch and/or rail. In various designs, the cartridge is arranged to be slid into or inserted into the 3-D printer using the engagement element. Generally, the cartridge is removable e.g., in various embodiments, it may be easily and repeatedly engaged with and withdrawn from the 3-D printer105, and is not (permanently) attached with adhesive, screws and/or bolts to the printer105.

The use of the cartridge offers various benefits. For one, it prevents the deposition material and/or the feed mechanism from being exposed. This helps prevent dirt and oil from entering the feed mechanism and causing a clog. Additionally, the user need not manually insert a filament or deposition material into the nozzle assembly. Instead, in various designs, the filament is pre-inserted into the nozzle assembly and encased in the housing. Thus, once the cartridge is engaged with the printer, the filament is already properly positioned within the cartridge so that it can be heated and dispensed to form the desired object on the platform.

When the cartridge100is properly engaged with the printer105and object data has been received from the computing device115, the 3-D printer105is arranged to determine the printer operations necessary to form the desired object. Generally, the 3-D printer105includes a printing compartment and a platform. The cartridge provides a nozzle assembly and a supply of deposition material. The 3-D printer105is arranged to dispense the deposition material from the nozzle assembly in order to form the object indicated in the data received from the computing device115.

Various implementations of the 3-D printer105include features that make the printer easier to use and calibrate. In some embodiments, for example, the platform of the printer includes a contact. The contact, which may include a button and/or a sensor, is arranged to generate a signal when it has been touched by the nozzle. Prior to printing, the 3-D printer causes the nozzle to touch the contact and uses the resulting signal to help determine the location of the nozzle relative to the platform. Unlike some conventional printer designs, there may be no need for the nozzle to touch multiple different points on the platform in order to properly calibrate the printer. This helps reduce or eliminate the delay, inaccuracy and frustration resulting from such calibration procedures.

Additionally, various designs of the 3-D printer105involve a nozzle and a nozzle assembly that do not move during the operation of the printer and/or the dispensing of deposition material from the nozzle. For example, the printer may be a polar coordinate printer. In some implementations, the printer is arranged to rotate, raise, lower and otherwise move the platform. The nozzle, however, does not move while dispensing deposition material and is fixedly attached with the cartridge.

Many 3-D printers are Cartesian printers i.e., in which the nozzle moves and is repositioned while deposition material is dispensed. One disadvantage of such printers is that they require extremely flat platforms. Even a slight deviation in the alignment of the platform can cause the nozzle to either dig into or drift too far from the surface of the platform. As will be discussed later in the application, such problems are greatly reduced in some of the 3-D printer designs described herein.

A 3-D printer design with a non-moving nozzle also works well with the aforementioned cartridge design. If the aforementioned cartridge design were used and the printer were required to move the nozzle during the printing process, then the entire cartridge and its store of deposition material would have to be constantly in motion. Alternatively, the nozzle of the cartridge could be flexibly attached (e.g., using a flexible tube) with the cartridge, which would allow the nozzle to be moved independently from the cartridge. However, such a design may have other problems. For instance, it is easy for a clog to develop in the flexible tube that connects the cartridge with a separated nozzle. Additionally, the constant motion of the flexible tube can increase the chance that the deposition material or filament in the tube is warped or broken. Thus, it has been determined that for various applications, the aforementioned cartridge design works particularly well with the polar coordinate printer or a printer in which the nozzle is not required to move during the operation of the printer. Put another way, in various embodiments, the nozzle is not coupled with deposition material in the cartridge through a flexible tube, but instead the nozzle is fixedly attached with the housing of the cartridge. In some embodiments, any tube that connects the nozzle with the cartridge stays within the housing of the cartridge during the operation of the printer and/or does not flexibly bend and move during the printing process.

Referring next toFIG. 2A, a cartridge200according to a particular embodiment of the present invention will be described. The cartridge100illustrated inFIG. 2Amay be the cartridge100illustrated inFIG. 1. The cartridge100includes housing205, a storage compartment220, a feed mechanism233, deposition material210and a nozzle assembly225. A magnified view of the nozzle assembly225is provided inFIG. 2B. It will be understood that, in some embodiments, a 3-D printer can support multiple cartridges. Each of the cartridges can be a self-contained cartridge and each cartridge can contain either the same or a different type of deposition material in terms of color, consistency, texture, and/or chemistry. Each of the self-contained cartridges can be readily removed from or attached to the 3-D printer by a user to facilitate color and material variations as well as to remedy material or technical issues with the 3-D printer. It will be understood that, in embodiments having multiple cartridges, a different nozzle can be provided for each cartridge.

Housing205is arranged to cover and protect the internal components of the cartridge200. The housing205may be made of any suitable material, including but not limited to metal, ceramic and plastic. In various embodiments, the housing205is in the form of a hard, substantially inflexible shell that almost entirely encases the nozzle assembly225, the deposition material210and/or other internal components, although portions of the nozzle assembly225(e.g., at least a portion of the nozzle, the heater receiving element, etc.) may be exposed through openings or apertures in the housing.

The exterior of the housing205may include features that help facilitate its engagement with the 3-D printer. In some designs, there are one or more engagement elements234on the exterior of the housing205. Each engagement element may be but is not limited to a slot, a rail and/or latch. One particular design involves a rail (e.g., a structure that extends along an axis and extends out of a surface of the cartridge) that is arranged to slide into a slot on the exterior of a 3-D printer.

The interior of the housing includes a storage compartment220. The storage compartment220is a space within the housing205that is arranged to contain deposition material210. The deposition material210may be any suitable material that can be extruded or dispensed through the nozzle assembly225to form the desired object. For instance, the deposition material may be but is not limited to polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), any suitable form of plastic and a food material.

The deposition material210may be stored in any suitable form. In the illustrated embodiment, for example, the deposition material210is in the form of filament. The filament is coiled around a hub215, which is part of or attached with the housing205. In other embodiments, the deposition material is in the form of pellets or any other suitable shape.

The feed mechanism233is any suitable structure that is arranged to help direct the deposition material210towards and/or through the nozzle assembly225. In the cartridge200illustrated inFIG. 2A, for example, a portion of the filament is uncoiled from the spool215and extends through the feed mechanism233and the nozzle assembly225. In this example, the feed mechanism233includes a pressure roller235and a feed gear212. As will be discussed later in the application, the feed gear212is driven by a pinion in a 3-D printer when the 3-D printer is engaged with the cartridge200.

In the illustrated embodiment, the feed gear212is in physical contact with the filament and, when rotated, helps push the filament through the nozzle assembly225. The pressure roller235is positioned at an opposing side of the filament relative to the feed gear212. The pressure roller235applies pressure onto the filament and helps stabilize it as it is moved through the nozzle assembly225. The pressure roller235and the feed gear212are positioned close to one end of the nozzle assembly. It should be appreciated that the feed mechanism233may have a different design and/or include fewer or more components than what is illustrated inFIG. 2A. For instance, the feed mechanism233may include different numbers of rollers, gears or other components such as a funnel, tubing, etc., which help guide the filament/deposition material towards the nozzle assembly.

Referring next toFIG. 2B, the nozzle assembly225illustrated inFIG. 2Awill be described. The nozzle assembly225includes a nozzle260, a heater receiving element250, a heat sink255, a tube270and an insulating layer275. It should be noted that the illustrated embodiment is intended to be exemplary and other embodiments are also contemplated that may depart from the design shown therein.

The tube270may be any hollow structure arranged to help transport the deposition material210through the nozzle assembly. In the illustrated embodiment, for example, one end253aof the tube is arranged to receive the filament/deposition material210from the storage compartment220. The other, opposing end253bof the tube is attached to the nozzle260. The tube270may be made of any suitable material, including but not limited to metal, ceramic and plastic.

An insulating layer275covers at least portions of the tube270and is arranged to help prevent heat from escaping the nozzle assembly225into the ambient environment. In the illustrated embodiment, the insulating layer275covers all exposed surfaces of the tube270. The insulating layer may be made of any suitable thermally insulating material, such as polytetrafluoroethylene (PFTE).

In this design, a heat sink250is (directly) attached to the tube270and is arranged to help dissipate heat from the nozzle assembly225. The heat sink250may be made of metal and/or any suitable thermally conductive material. The heat sink250may take a variety of different forms e.g., a comb-like shape. The heat sink250may be positioned in any suitable location in the nozzle assembly225e.g., as indicated in the figure, at the midsection of the tube270between the two end253aand253b.

The heater receiving element250is arranged to receive the heater element from a 3-D printer when the printer is engaged with the cartridge200. The heater receiving element250may take a variety of forms. In the illustrated embodiment, for example, the heater receiving element250forms a tube or socket with an open end into which the heater element can be inserted. The open end of the heater receiving element250may be flared, as shown in the figure, to help facilitate the insertion of the heater element. The other (closed) end of the heater receiving element250is attached (directly) to the tube270(e.g., at end253bof the tube), the nozzle260or another suitable location on the nozzle assembly.

In various implementations, the heater receiving element250is attached at a location on the nozzle assembly225that is adjacent to or directly at the nozzle260. When the heating element of a printer is inserted into the heater receiving element250, heat passes into the nozzle assembly225and melts a portion of the filament/deposition material210. For instance, in the illustrated embodiment, there is a portion of the filament/deposition material210that extends through the nozzle assembly225and that is adjacent to the location on the nozzle assembly225where the heater receiving element250is attached. In various embodiments, the heat causes this portion of the filament/deposition material to change from a solid state to a plastic/glass state, so that it can be dispensed through the nozzle260.

The nozzle260may be any suitable structure arranged to extrude or dispense deposition material onto a platform in the 3-D printer to form the desired object. The nozzle260may be made of a wide variety of materials and/or have various forms. In the illustrated embodiment, for example, the nozzle is made of metal and has a tapered tip265through which extrudate is released, although this is not a requirement and the nozzle260may have a different shape or configuration (e.g., that of a straight, non-tapered tube.)

Referring next toFIG. 3, an exploded view of a cartridge300according to another embodiment of the present invention will be described. The cartridge300may have any of the features described in connection with cartridge200ofFIG. 2A.

In this particular embodiment, the housing of the cartridge300is formed from at least three parts (parts305a-305c.) The parts, when fitted together, collectively encase and form a protective shell around an interior storage compartment. The housing may be made of any suitable material. For example, it may be made of a hard, relatively inflexible plastic. A hub310is positioned in the storage compartment. A spool315of filament/deposition material is rotatably mounted on the hub. The filament may be made of any suitable deposition material e.g., PLA, ABS, etc.

FIG. 3also displays various embodiments of a nozzle assembly325and a feed mechanism333. The nozzle assembly325includes a nozzle365, heat sink355and a tube370, which may be covered in an insulating material. The feed mechanism333includes a feed gear312and one or more rollers335. The one or more rollers and the feed gear are engaged with and/or are in physical contact with the filament357that extends through the tube370and the nozzle assembly325. The feed gear312includes a cylinder with two ends. At one end, there is a toothed gear that is arranged to engage a feed pinion from the 3-D printer. When the pinion is powered and rotated by the printer, it rotates the feed gear as well. The other end, when rotated, is arranged to apply force onto the filament to help push it through the nozzle assembly325. Just before or as a portion of the filament passes through the nozzle, it is heated by the heater receiving element350. Thus, filament dispensed from the nozzle is in a plastic/glass state.

Referring next toFIGS. 4A and 4B, a three dimensional printer400according to a particular embodiment of the present invention will be described. The 3-D printer400may be any suitable printer that is arranged to form objects using any known three dimensional printing technique e.g., additive manufacturing, fused deposition modeling, etc. The 3-D printer400may be, for example, the printer105ofFIG. 1. The printer400includes a housing405, an inner compartment410, a cartridge interface415and a platform assembly440. Near or at the cartridge interface415is a feed pinion425, feed gear motor430and a heating element435. As indicated inFIGS. 4A and 4B, the platform assembly440includes a platform445, a contact450, a platform turning mechanism455, slider460, a table465, a control system420and associated motors and gears. It should be appreciated that the illustrated printer is intended to be exemplary and non-limiting, and that a wide variety of different printer systems (e.g., Cartesian, polar coordinate, etc.) with fewer or more components may be used.

The housing405is arranged to protect and/or encase internal components of the printer400. The housing405may be made of any suitable material, including but not limited to plastic and metal. In various embodiments, the housing405includes a door407that can be opened to obtain access to the inner compartment410.

The housing405and the printer400may take a wide variety of different forms. In the illustrated embodiment, for example, the housing405has opposing top and bottom surfaces408/409. The top surface408is the location at which a cartridge interfaces with the printer e.g., the location of cartridge interface415, feed pinion425and the heating element435. The bottom surface409is arranged to be placed on an underlying surface e.g., the floor or a table. This above design is intended to be exemplary, however, and it should be appreciated that the housing405and the printer400may have any suitable arrangement, configuration and/or shape.

The inner compartment410is arranged to be a space within the housing405in which printing takes place. In the illustrated embodiment, the platform assembly440, which includes a platform445, a slider460and a table465, rests on a bottom surface417of the compartment. The opposing top surface418of the compartment410shares a housing wall with the cartridge interface415and/or is arranged to help physically support a nozzle assembly225of a cartridge200, so that deposition material can be dispensed over the platform445through the nozzle assembly225.

The platform445is any suitable structure that is arranged to receive deposition material dispensed from the nozzle assembly225. In the illustrated embodiment ofFIGS. 4A and 4B, for example, the printer400is positioned such that deposition material is dispensed directly onto a top surface447aof the platform445to form the desired object. The platform445may be of any suitable size and shape. In various implementations, the top surface447aof the platform is circular.

As shown inFIG. 4B, a contact450is positioned on the platform445. The contact450may be any structure, mechanism or device on the platform that is arranged to help generate a signal when it is touched e.g., by the nozzle260of the nozzle assembly225. In the illustrated embodiment, for example, the contact450is a mechanical button that extends at least partially through the platform. In other embodiments, the contact450is or includes an electrical contact, a capacitive sensor, a magnetic sensor or any other suitable type of sensor arranged to detect the touching or proximity of an object (e.g., the nozzle.) In various implementations, the contact450is a structure physically separate from the platform, while in other implementations, it forms a part of or is integrated into the platform.

In the illustrated embodiment, for example, the contact/button extends entirely through the platform445, the platform turning mechanism455and at least partially through the slider460. Put another way, there are apertures in the platform and platform turning mechanism that are aligned with one another, thus allowing the contact/button to extend through them. In this example, the top surface447aof the platform445and the top surface452aof the contact/button are coplanar. Additionally, the top surface of the contact/button is exactly at the center of the circular, top surface of the platform. In other designs, however, the contact and platform may have different arrangements. For example, in some implementations, the contact450may be not extend entirely through the platform445and/or may be situated in a recessed region in the platform.

The contact450is coupled with the control system420. When the contact450is touched and/or when the contact/sensor detects the proximity of a particular object (e.g., the nozzle260of a cartridge200), it is arranged to generate a signal. The control system420receives the signal and, in response, sends commands to other components in the printer400. As will be discussed in greater detail later in the application, the control system420determines the proper position of the nozzle relative to the top surface of the platform in part based on the signal.

In the example illustrated inFIGS. 4A and 4B, underlying the platform445is a platform turning mechanism455. The platform turning mechanism is arranged to physically support and/or rotate the platform e.g., around the Z axis475. In some embodiments, the platform turning mechanism is a circular, rotatable gear. A platform turning gear480engages the platform turning mechanism and drives its rotation. A platform turning motor482provides power to and drives the platform turning gear480. In this example, the platform445is fixedly attached with the underlying platform turning mechanism455, so that when the platform turning mechanism455rotates, the platform rotates as well.

In this example, the platform turning mechanism455is sandwiched between the platform445and the slider460. The slider460is any suitable structure that is arranged to help move the platform along an R axis476i.e., a lateral axis that is perpendicular to the Z axis. (Note that in some embodiments, the R axis may also be extending directly out of the page, rather than across the page.) In various embodiments, the platform445and/or the platform turning mechanism455are fixedly attached with the top surface461aof the slider460, so that when the slider moves, the platform and/or the platform turning mechanism move in tandem. A slider gear462, which is driven by the slider motor463, is physically engaged with the slider460. When the slider gear462is powered by the motor463, the slider gear462rotates, which causes the slider460to move along the R axis.

The table465is any suitable structure arranged to help physically support, raise and lower the overlying platform445, platform turning mechanism455and/or the slider460. In the illustrated embodiment, for example, the table465is fixedly attached with a Z axis gear467, which is powered by a Z axis motor468. The Z axis gear467engages a rail485that extends in a direction parallel to the Z axis475. When the Z axis gear is rotated, the table465and other components that overlie the table (e.g., the platform445, the platform turning mechanism455and the slider460) move upward or downward within the compartment i.e., along the Z axis475.

The table465may have a variety of designs. For example, in the illustrated embodiment, the table465is at least partially hollow and contains an internal space. In the space are circuitry, memory and/or one or more processors that make up the control system420. (Note that the in some designs, the control system420may be positioned in a different location of the printer.) Other components (e.g., motors or gears) may also be situated in the space within the table.

On one or more exterior surfaces of the housing405of the printer400is a cartridge interface415. The cartridge interface415is any structure arranged to engage with the printer. Any suitable locking or attachment mechanism may be used in the cartridge interface. In some implementations, for example, the cartridge interface415includes a rail, a slot, a latch, a fastener or some other attachment/connecting apparatus. Generally, the cartridge interface415helps to securely attach the cartridge with the printer, as well as help properly position the cartridge200so that printing can begin using the deposition material210and nozzle assembly225in the cartridge200.

The heating element435is any suitable structure in the printer400used to heat deposition material in the cartridge. The heating of the deposition material is performed so that the formerly solid deposition material can be put into a state such that it can be easily dispensed from the nozzle assembly225of the cartridge200. Generally, the heating element435is arranged to engage the heater receiving element250of the cartridge200. For example, the heating element435may be a tube270or structure that is arranged to extend through an opening in the cartridge housing such that is positioned adjacent to the tube or nozzle of the nozzle assembly in the cartridge. The heating element435generates heat, which helps melt deposition material in the tube or nozzle.

The heating element435may have a wide variety of designs. In some implementations, for example, the heating element435includes a hollow tube made of a thermally conductive material e.g., metal. Inside a space within the tube is a (metallic) wire or coil. To generate heat, the 3-D printer400runs a current through the wire. There may also be a temperature sensor attached on the outside or inside of the heating element435, so that the control system420of the printer400can determine whether a predetermined, desired temperature has been reached.

The control system420of the printer400may adjust the temperature of the heating element, depending on the type of deposition material used. For example, if PLA is used as a deposition material, in various embodiments, the printer may heat the heating element to a temperature of over 150° F. or between 170 and 230° F. If ABS is used, the printer may be arranged to heat the heating element to a temperature of over 220° F. or between 220 and 280° F. Generally, the printer may heat the heating element to a wide range of temperatures e.g., whatever temperature is needed to change deposition material to a plastic or glass state at a desired rate.

The heater element435may be positioned in a variety of locations and configurations. For example, the heater element435may be exposed outside of the housing of the printer. In other embodiments, the heater element435is positioned within the housing, but is accessible through a door or opening in the housing405.

The printer also includes a feed pinion425. The feed pinion425is a gear or other structure that is arranged to engage the feed gear212on the cartridge200and help drive the filament/deposition material through the nozzle assembly225of the cartridge200. In various embodiments, the feed pinion425is exposed outside of the housing405of the printer400, so that it has easy access to the cartridge. In other embodiments, the pinion425is within the housing, but is accessible through a door or opening in the housing. In the illustrated embodiment, the feed pinion425is driven by a feed pinion motor430.

The feed pinion425and/or feed pinion motor430may be positioned in various locations on the printer. In the illustrated embodiment, for example, the feed pinion425and the feed pinion motor430are positioned on a top side/surface408of the printer. When the cartridge is inserted into or engaged with the top side of the printer, the feed pinion425is in a position to engage the feed gear212of the cartridge200.

Referring next toFIG. 5, a perspective view of selected internal components of a 3-D printer according to a particular embodiment of the present invention is described.FIG. 5illustrates a 3-D printer500(which may have any of the features and components of the printer400ofFIG. 4) that includes a feed pinion525, feed gear motor530, a heating element535, a platform545and rails585for vertically raising and lowering the platform. For illustrative purposes, the platform545is transparent so that the underlying platform turning mechanism580can be seen.

In this particular embodiment, the platform545is circular and is centered over the underlying platform turning mechanism580, which is also circular. The platform545is fixedly attached with the platform turning mechanism580so that when the mechanism rotates, the platform rotates.

The platform545is also attached with a Z axis gear567, which is driven by a Z axis motor468. When the Z axis motor468causes the Z axis gear567to rotate, the gear567moves along the rail585along the Z axis575, together with the platform545.

Referring next toFIGS. 6A-6C, various side views of a 3-D printer600and a cartridge690according to a particular embodiment are described. The printer600may have any of the features or components of other printers described herein (e.g., printer400ofFIG. 4.)FIGS. 6A-6Cillustrate various ways in which a platform645and/or connected components (e.g., a platform turning mechanism, a slider and a table) may be moved within the compartment of the printer. In the illustrated embodiment, the printer600includes a platform645and a table665. The table665underlies and helps physically support the platform645.

InFIG. 6A, the platform645is rotating, as indicated by the arrows. More specifically, it is rotating around a Z axis675that extends vertically up through the printer i.e., an axis that extends perpendicular to the top surface647aof the platform645. It should be noted that in this example, the table is not necessarily rotating. Rather, there may be a gear (e.g., platform turning mechanism, which is not shown) that is sandwiched between the table and the platform. The platform645is attached to the gear and rotates in tandem with the gear, while the table remains still and/or does not rotate.

InFIG. 6B, the platform645is moving in a lateral direction i.e., in a direction that is perpendicular to the Z axis675. In this example, the table665is not necessarily moving in the same direction. There is a structure (e.g., a slider, which is not shown) that is sandwiched between the table665and the platform645. The slider is fixedly attached with the platform, such that when the slider moves in the lateral direction, the platform645moves laterally in tandem, while the table remains still.

FIG. 6Cindicates that the platform645is capable of being raised and lowered. (InFIGS. 6A and 6B, the platform was in a raised position, and inFIG. 6Cit has been lowered.) The raising and lowering involves moving the platform vertically along the Z axis675. In this example, the table665is capable of moving up and down as described above. Since the platform645rests on the table665, the platform moves up and down in tandem with the table.

Any of the movements described above may be driven by various gears and motors described in connection withFIGS. 4A and 4B. For example, the vertical raising and lowering of the platform may be performed using the Z axis gear467, Z axis motor482and the table. The lateral movement of the platform may be performed using the slider gear462, the slider motor463and the slider460. The rotation of the platform may be performed using the platform turning mechanism455, the platform turning motor482and the platform turning mechanism455.

Referring next toFIG. 7, an exploded view of various components inside the compartment of an example printer700(e.g., which may be printer400ofFIG. 4) will be described. The components include a platform745, a platform turning mechanism755, a contact750, a slider760and a table765. The components may have any of the features of the corresponding components described inFIGS. 4A and 4B.

In this particular embodiment, the platform745includes a top surface747athat is circular. At the center of the top surface747ais an aperture that extends entirely through to an opposing bottom surface of the platform. The bottom surface of the platform rests on and/or is fixedly attached to an underlying platform turning mechanism755.

The platform turning mechanism755also includes a top surface756aand an opposing bottom surface that have circular shapes. At the center of the top surface of the mechanism is an aperture that extends entirely through the mechanism to the bottom surface. In various embodiments, the edges of the mechanism are toothed, so that they can engage the platform turning gear780.

The slider760includes a top surface761aand an opposing bottom surface. The bottom surface of the platform turning mechanism rests on the top surface of the slider. The top surface of the slider may have grooves, rails or other features that allow the platform turning mechanism to freely turn without causing the slider to turn as well. In some embodiments, at least a portion of the edge of the slider760is toothed, so that it can easily engage a slider gear762. When a slider motor763drives the slider gear762, it rotates, which causes the slider to move in a lateral direction. The slider carries the overlying platform, contact and/or platform turning mechanism, such that they move laterally in tandem with the slider.

In this particular embodiment, the contact750is in the form of a button. The button is arranged to transmit a signal when it is pressed (e.g., by the nozzle260of the cartridge200.) In this example, the button includes a base752having a cylindrical shape and a depressible trigger that also has a cylindrical shape. The diameter of the base is larger than the diameter of the trigger. The trigger is inserted into the base and extends perpendicular to the top surface of the base.

The trigger751is capable of being in at least two positions. The first position is when the trigger extends a particular amount out of the top surface of the base752, which is its default position when no pressure is applied to it. The second position is when pressure is applied to the trigger (e.g., by the nozzle of a cartridge), which causes the switch to extend less out of the top surface of the base. A sensor or mechanism within the mechanism detects this pressure and transmits a signal to the control system420of the printer.

The button750is arranged such that it extends through the apertures in the platform745, the platform turning mechanism755and the slider760. In various implementations, the trigger portion of the button extends through the apertures in the platform745and/or the platform turning mechanism755, while the base portion of the button is seated in a recessed region or aperture in the top surface761aof the slider760. In various implementations, the top surface of the switch is coplanar with the top surface756aof the platform.

In the embodiment illustrated inFIG. 7, the bottom surface of the slider is positioned in a recessed region or slot in a top surface769aof the table765. Thus, in various designs, the top surface of the slider and the top surface of the table are coplanar. The slider is able to slide freely along the recessed region, which defines a slot in the top surface of the table that conforms to the shape of the slider.

The table765may or may not have a bottom surface. In some designs, the table is a hollow shell or housing, with an open space defined by the top surface and perpendicular side surfaces of the table. In various embodiments, circuitry (e.g., a processor and memory) for the control system420and/or motors and gears may be situated in this space. In the illustrated example, the Z axis motor768and/or a Z axis gear767are attached to one or more of the side surfaces of the table765. The gear767, when rotated, causes the platform and the overlying components (e.g., the platform, the platform turning mechanism, the slider) to rise or lower within the compartment i.e., move vertically along the Z axis.

Referring next toFIGS. 8 and 9, diagrams illustrating the engagement of the cartridge200and the 3-D printer400according to a particular embodiment of the present invention will be described. In this example, the cartridge200and the printer400are the cartridge and printer illustrated inFIGS. 2A and 4A, respectively.

In the illustrated embodiment, the cartridge200is oriented so that its bottom surface201a(out of which a nozzle260extends) is facing downward i.e., in a direction that is perpendicular to the bottom surface417of the compartment410in the printer400. To engage the cartridge200with the printer400, the cartridge200is moved laterally into or along the printer i.e., in a direction that is a parallel to the top surface408of the printer400. Other movements (e.g., vertical movements) may be used in addition to or instead of this lateral movement to engage the cartridge200with the printer400.

In various embodiments, the top surface408of the printer supports or includes a cartridge interface415with one or more engagement elements e.g., a rail, a slot, a latch, etc., which helps secure the cartridge200to the printer400. In the illustrated embodiment, for example, the top surface408of the printer includes or supports one or more slots or recessed regions that extend in a direction parallel to the top surface. The cartridge200also includes one or more engagement elements234(e.g., a rail) that is inserted into the slot. The rail of the cartridge200is then slid along the slot of the printer400until the rail reaches the end of the slot. At that point, the cartridge200is fully seated in the printer400.

In this example, the lateral motion of the cartridge200creates at least two points of engagement. For one, the lateral motion causes the heater element435of the printer400to engage or become inserted into the heater receiving element250of the nozzle assembly225. Also, the lateral motion of the cartridge200simultaneously causes the feed gear212of the cartridge to physically engage the feed pinion425of the printer.

As a result of the above engagement, the heating element435of the printer400and the feed pinion425of the printer400are able to perform their intended functions. That is, the heater element is arranged to generate heat and use the heat to help melt deposition material/filament in the nozzle assembly225to a plastic state. The heat generated by the heating element435flows upward through the nozzle assembly225and dissipates out through the front grate346(FIGS. 3 and 13). As shown inFIG. 3, a cavity348is provided to facilitate heat flow to prevent heat build-up in the cartridge200and deformation of the deposition material. The feed pinion425, which is powered by the feed pinion motor430of the printer, is arranged to rotate, which in turn rotates the feed gear212of the cartridge200. This rotation helps move the deposition material/filament through the nozzle assembly.

When the cartridge200is fully seated in and engaged with the printer400as described above, at least a portion of the nozzle265is exposed and/or extends beyond the housing405and is positioned within the inner compartment410of the printer. The nozzle260faces in a downward direction i.e., in a direction parallel to the Z axis and/or in a direction that is perpendicular to the bottom surface of the compartment417or the top surface of the platform445. Accordingly, the nozzle460is well positioned to dispense deposition material over the platform.

Referring next toFIGS. 10 and 11, a cartridge1050and a printer1000according to another embodiment of the present invention will be described. For the purpose of illustration and clarity, the housings of the cartridge and printer are drawn to be transparent so that their inner components can be seen.FIGS. 10 and 11indicate an example method of attaching the cartridge1050to the printer1000.

In this example, the cartridge1050includes a spool of deposition material/filament1060, a feed gear1055, a heater receiving element1065, as well as any of the cartridge components described in connection with the cartridge200ofFIGS. 2A and 2B.

The spool1060forms a cylinder with opposing top and bottom surfaces. In this example, the deposition material/filament is coiled to help form sides of the cylinder. The spool is situated within the cartridge such that the top and bottom surfaces of the spool are parallel and/or adjacent to opposing side surfaces1051aof the cartridge1050.

A bottom surface1051bof the cartridge1050, which is perpendicular to the side surfaces, is arranged to rest on the top surface1001aof the printer1000when the cartridge is fully seated in the printer, as shown inFIG. 11. A nozzle of a nozzle assembly in the cartridge1050points in the same downward direction that the bottom surface1051bof the cartridge1050faces.

In the illustrated embodiment, the cartridge1050also includes an attachment surface1051c, which is perpendicular to both the side surfaces1051aand the bottom surface1051bof the cartridge. The heater receiving element1065of the cartridge extends in a direction perpendicular to this attachment surface. The heater receiving element may be at least partially exposed and positioned outside the attachment surface, or be within the housing of the cartridge e.g., accessible through an opening or a door in the housing.

There is also a feed gear1055that is positioned near, at or on the attachment surface. The feed gear1055may be at least partially exposed outside of the cartridge housing, or positioned within the housing e.g., accessible through an opening or a door in the housing. In this particular embodiment, the feed gear1055has the shape of a flat cylinder. The top and opposing bottom surfaces of the gear are connected with toothed side surfaces. In this example, the feed gear is positioned such that the toothed surfaces face outward in the same direction as the attachment surface1051cand the top/bottom surfaces of the feed gear are parallel to the side surfaces of the cartridge.

The printer1000includes a base structure1010and a top attachment structure1005. The base structure1010includes opposing top and bottom surfaces. The top surface of the printer1001a, as shown inFIG. 11, is arranged to support the bottom surface of the cartridge. The attachment structure1005is a structure that is positioned on or extends out of the top surface1001aof the base structure.

In the illustrated embodiment, the feed pinion1015and the heating element1020of the printer are at least partially covered by, supported by or positioned within the attachment structure1005of the printer1000. In this example, the attachment structure1005forms a slot/recessed region in cooperation with the top surface1001aof the base structure. The cartridge1050is arranged to fit into this slot/recessed region. When the cartridge is fully seated in the slot/recessed region of the printer, the heating element1065of the printer extends into the heater receiving element1065of the cartridge, as shown inFIG. 11. Additionally, the feed pinion1015of the printer engages the feed gear1055of the cartridge.

It should be noted that the orientation of the heater receiving element in the cartridge is somewhat different in the cartridge ofFIG. 10than it is in, for example, the cartridge ofFIG. 9. InFIG. 10, the heater receiving element1065is facing outward and away from the cartridge. That is, the aperture in the heater receiving element through which the heating element is inserted faces the printer and/or faces in the same direction as the attachment surface.

InFIG. 9, however, the design of the heater receiving element250is somewhat different. The heater receiving element250inFIG. 9is facing inward. Put another way, the cartridge200includes a bottom surface201athat rests on the printer, and two opposing side surfaces (first and second side surfaces201b/201c) that are perpendicular to and/or at opposing edges of the bottom surface201a. The heater receiving element260is substantially closer to the first side surface than the second side surface, but does not face in the same direction as the first side surface. Rather, it faces in the same direction as the second side surface.

Referring next toFIGS. 12 and 13, an enlarged perspective view of the engagement between the heating element of the printer and the heater receiving element of the cartridge.FIG. 12illustrates a particular implementation of the cartridge200and printer400inFIG. 9, in which the heater receiving element250of the cartridge and the heating element435of the printer400are close to one another, but have not yet fully engaged one another.

As seen inFIG. 12, the bottom surface201aof the cartridge, which rests on a top surface of the printer, includes an aperture202. A portion of the nozzle260and/or nozzle assembly225extends out of the aperture and is exposed outside the housing205of the cartridge200. In the illustrated embodiment, much of the tubing is almost entirely encased in the housing, but enough of the nozzle assembly225extends through the aperture202such that the nozzle260and the heater receiving element250are exposed outside of the cartridge housing.

The bottom surface201aof the cartridge200includes a rail or ridge1205that is shaped to engage a slot1210at the edge of a top surface of the printer408. The ridge, which extends along an R axis476, is arranged to slide along the slot. That is, the cartridge is arranged to slide in a direction that is parallel to the top surface of the printer408. As the cartridge is slid in this manner, the heating element435of the printer400simultaneously moves further into the heater receiving element250of the cartridge200. That is, the heating element enters and extends into the opening in the heater receiving element.

The heating element435is in the shape of a cylinder or bar that is arranged to fit into the opening of the heater receiving element250. In the illustrated embodiment, there is a space or opening1220in the housing of the printer400where the heating element435is positioned. This space helps prevent the heating element from heating and damaging parts of the housing or other components of the printer.FIG. 13illustrates the heating element435and heater receiving element250ofFIG. 12when they are fully engaged with one another. That is, inFIG. 13, the heating element435of the printer400is inserted into the heater receiving element250of the cartridge200.

Referring next toFIG. 14, a diagram of selected components of a cartridge200and a printer400according to a particular embodiment are described. The components are illustrated at a point in time in which the cartridge and the printer are fully engaged with one another. They may be, for example, components of the cartridge200and printer400ofFIGS. 8 and 9.

In the illustrated embodiment, the printer includes a feed pinion motor425and a feed pinion430. The feed pinion motor drives the feed pinion, causing the feed pinion to rotate. In this example, the feed pinion is a toothed gear that engages the toothed gear of a feed gear212in the cartridge200. At one end of the feed gear is a toothed gear. The opposing end is engaged with deposition material/filament (not shown) that is inserted into the nozzle assembly225. The rotation of the printer feed pinion430causes the interlocked cartridge feed gear212to rotate as well, which helps push the deposition material/filament into and through the nozzle assembly225. In the illustrated embodiment, the area of engagement where the feed gear structure and a pressure roller engage the deposition material/filament is adjacent to or very close to the opening in the nozzle assembly225where the deposition material/filament enters.

The deposition material/filament enters one end253aof a tube270of the nozzle assembly225, which is covered in a thermally insulating material275. It extends through a space within the tube to an opposing end253bof the tube, which is connected with a nozzle260.

The heating element435of the printer400extends through an opening in a heater receiving element250of the nozzle assembly225. In the illustrated embodiment, the heater receiving element forms a socket or tube that the heater receiving element is inserted into. When the heating element is fully inserted into the heater receiving element, it is close to or adjacent to a space in the tube that is close to the nozzle (e.g., at end253bof the tube.) Alternatively, the heater receiving element250may be coupled to the nozzle itself. When the heating element435is heated, the heat is transmitted through the tube or nozzle, which causes the deposition material/filament within to change from a solid state to a plastic state. When the printer is printing, the deposition material is then dispensed from the nozzle into the compartment410of the printer400and onto the platform445. According to an embodiment, the heating element435is spring-loaded with force to thermally couple with heater receiving element250.

Referring next toFIGS. 15 and 16, a method1500of using a three dimensional printer according to a particular embodiment of the present invention will be described.FIG. 15is a flow diagram illustrating the method1500.FIG. 16illustrates a cross-sectional view of various steps in the method, which involve a nozzle260and a platform445. In this example, it is assumed that the method1500is performed using the printer400illustrated inFIG. 4Aand the cartridge200illustrated inFIG. 2A. The cartridge200and the printer400are fully engaged with one another e.g., as illustrated inFIGS. 8 and 9. However, it should be appreciated that the method1500may be performed using any suitable printer, cartridge, nozzle assembly and platform.

Initially, at step1505, a user activates a three-dimensional printer400. The user may, for example, touch or trigger a power switch on the printer. In other embodiments, the user may activate the printer remotely e.g., using a wireless connection, a smart phone and/or another portable device.

In various embodiments, as shown inFIG. 16A, when the printer400has just been activated, the platform445and the nozzle260are separated from one another. At step1510, the printer400raises the platform445to bring it in closer proximity to the nozzle260. This raising of the platform may be performed as previously described e.g., in connection withFIGS. 4A, 4B and 6.

At step1515, the printer400positions the nozzle260such that it touches the contact450on the platform445. An example of this is shown inFIG. 16B, in which the tip265of the nozzle260applies pressure to the contact450. It should be noted that the contact450may have any suitable design or architecture (e.g. as described in connection withFIG. 4A.) For example, the contact450may be an electrical contact, a sensor, or a button. This step may involve further raising the platform so that a (stationary) nozzle touches the contact450on the platform445.

As discussed in connection withFIGS. 4A and 4B, when the nozzle260touches and/or applies pressure to the contact450, the contact transmits a signal indicating that this has happened. At step1520, a control system420of the printer400receives this signal.

In various embodiments, the information indicated by the signal may be helpful for several reasons. For one, the control system420is informed that the nozzle has reached the top surface of the platform. Based on this information, the control system420can determine a suitable distance between the nozzle and the platform surface prior to printing. This is important because in various implementations this distance must be precisely determined. If the nozzle is too far from the surface of the platform during printing, the deposition material may fail to adhere to the surface of the platform, thereby causing a printing error. On the other hand, if the distance between the nozzle and the platform is too small, there is a risk that the deposition material dispensed on the platform will be squeezed and/or that the nozzle will drive into the surface of the platform.

Various existing printer designs have systems for determining a proper distance between the nozzle and the platform. For example, some systems use a sensor/detection mechanism that is outside of the platform. When the platform and/or the nozzle are repositioned such that they are touching one another, the sensor/detection mechanism is supposed to trigger. However, since the sensor/detection mechanism is outside of the platform itself, there is a possibility that it will not properly reflect the actual position of the nozzle relative to the platform. Put another way, to truly confirm the relative positions of the nozzle in the platform, in various applications it is desirable to use a sensor/contact that is actually in the same location as the area of interest i.e., where the nozzle touches the platform.

Additionally, as previously discussed, in some embodiments, the contact is positioned in the center of the top surface of the platform. For example, in some polar coordinate printer designs, the top surface of the platform that is arranged to receive the dispensed deposition material is in the shape of a circle, and the contact is in the exact center of the circle. When the nozzle is determined to have touched the contact, the control system is informed that the nozzle is also in the exact center of the platform. This is particular useful information for polar coordinate printer designs, in which printer operations are based on polar coordinates i.e., in terms of radius or distance from a center point.

Optionally, the printer400may redo some of the above steps in order to more precisely determine the position of the nozzle260. For example, in some embodiments, since the platform445begins at the bottom of the compartment of the printer, the printer raises it (e.g., step1510) fairly quickly until the nozzle touches the contact (e.g., step1515). This helps to save time during the startup process. However, it may be desirable to obtain a more precise determination of the relative positions of the nozzle and the platform. Accordingly, at step1525, the printer lowers the platform, thereby creating a distance between the nozzle and the platform. Then, at step1530, the printer causes the nozzle to touch the platform, which triggers the transmission of a signal indicating that action i.e., the printer repeats steps1515and1520. When causing the nozzle to touch the platform a second time, the printer may raise the platform more slowly than in step1510, so that it can more precisely determine the current location of the nozzle.

After the control system420of the printer400determines, based on the signal, that the nozzle has touched the contact450on the platform, the printer400repositions the nozzle260and the platform445to create a suitable distance between the nozzle and the platform (step1535andFIG. 16C). For instance, if A represents a predetermined distance between the top surface447aof the platform445and the nozzle260that is suitable for printing, in various implementations, the printer lowers the platform to create distance of A+B between the nozzle and the platform, where B represents a predetermined additional distance. The repositioning of the nozzle and the platform is based on the signal received in step1520i.e., they are based on the assumption that the signal helps accurately represent the location of the nozzle relative to the platform at that time.

Additionally, the printer may laterally reposition the nozzle relative to the platform, as shown inFIG. 16D. For example, if printing is to be performed in a polar coordinate printer, it is common for the printing process to start closer to the edge of the circular surface of the platform, rather than at the center of the platform. Thus, during this step, the printer may laterally move the platform so that the nozzle is in an appropriate position. As previously discussed, this may involve moving a slider460that underlies the platform445. This causes the platform to move laterally (e.g., along an R axis476) and positions the nozzle at a location that is closer to the edge of the top surface of the platform than the center.

At step1540, the printer400heats the nozzle assembly225. In various designs, it is not desirable to begin this heating process when the nozzle is too close to the platform, which is the reason why step1535is performed. As previously discussed, this process may involve heating the heating element435of the printer400, which is inserted into the heater receiving element250of the cartridge200. In various implementations, the printer continues to heat the heating element until a desired temperature has been reached, which may vary depending on the type of deposition material that is used. The control system420of the printer may determine the temperature at the heating element based on data received from a temperature sensor that is inside or coupled with the heating element.

After a suitable temperature has been reached and/or the heating process has been completed, at step1545, the printer400repositions the nozzle260in preparation for the dispensing of deposition material. To use the above example, the printer may then raise the platform a distance B, such that there is only a distance A between the nozzle and the top surface of the platform.

At step1550and as shown inFIG. 16E, the printer begins to dispense deposition material through the nozzle260over the platform445. During the printing process, the printer may laterally move the platform and/or rotate the platform so that the deposition material is dispensed in an appropriate pattern to form the desired object. In some printer designs, the printer may also/instead move the nozzle during the printing process.

The above method involves multiple, specific steps that are performed in a particular order. However, it should be appreciated that in some implementations of the method, the steps are reordered or modified. Additionally, one or more steps may be added or removed.

Additionally, the above method assumes a printer design in which the platform is capable of movement, but the nozzle is not capable of movement. However, this is not a requirement. That is, in some implementations, to bring the nozzle and platform closer together, the nozzle can be moved, rather than just the platform. Put another way, the use of the contact as described above is not limited to polar coordinate printers or printers that are only capable of platform movement, but rather to any suitable printer design (e.g., Cartesian printers, etc.)

Referring next toFIG. 17, a diagram of a cartridge and a three-dimensional printer according to a particular embodiment of the present invention will be described. This diagram illustrates an operation (e.g., step1515ofFIG. 15) in which the printer causes the tip of the nozzle to touch a contact on/at the platform. The illustrated cartridge and three-dimensional printer may be, for example, the cartridge200ofFIG. 2Aand the printer400ofFIG. 4A.

In this particular embodiment, the contact450is a mechanical button. The top surface452aof the button is substantially coplanar with the top surface447aof the platform445. In this example, the top surface of the button is also positioned at the center of the (circular) top surface of the platform. The button extends through apertures in the platform445, the platform turning mechanism455and the slider460. The bottom surface452bof the button, which opposes the top surface of the button, is positioned on the top surface of the table466a.

The table465may include one or more motors that help adjust the position of the platform. In this particular embodiment, a platform turning motor482is positioned within the table. The platform turning motor is coupled with a platform turning gear480that is positioned over the top surface of the table and underneath a bottom surface of the platform445. The platform turning gear480is physically engaged with the platform turning mechanism455.

Referring next toFIG. 18, a method1800for using a cartridge according to a particular embodiment of the present invention will be described. Initially, at step1805, a cartridge and a three-dimensional printer are provided. In the illustrated embodiment, the cartridge and printer are the cartridge200and printer400ofFIGS. 2A and 4A, respectively, although any cartridge or printer described herein may be used.

At step1810, the cartridge200engages the printer400. In some embodiments, for example, the cartridge is inserted into or locked into the printer. Various techniques for engaging the cartridge with the printer are described, for example, in connection withFIGS. 8 and 9.

At step1815, the cartridge200receives a heating element435of the printer400. For instance, the cartridge200may have heater receiving element250e.g., a tube that is positioned close to or adjacent to a nozzle of the cartridge200. The heating element of the printer can be inserted into an opening in the tube. The engagement between the heating element of the printer and the heater receiving element of the cartridge may be performed as described in connection withFIGS. 9, 12, 13 and 14.

At step1820, the cartridge200receives heat from the heating element435. In various embodiments, heat is transmitted from the heating element into a nozzle assembly225of the cartridge200via the heater receiving element250of the cartridge200. This helps to melt deposition material/filament inside of the nozzle assembly so that it can be dispensed over the platform to form an object.

At step1825, the cartridge200receives a feed pinion425of the printer400. The feed pinion of the printer engages a feed mechanism233in the cartridge200. The feed mechanism may include a feed gear that, when engaged and driven by the feed pinion, helps move the filament/deposition material through the cartridge and the nozzle assembly. This step may be performed using any of the techniques and structures described herein e.g., as described in connection withFIGS. 9, 10 and 11.

At step1830, the feed mechanism233in the cartridge200helps move deposition material through the cartridge200and the nozzle assembly225. In various embodiments, as described above, the feed gear212of the cartridge200is physically engaged with a portion of the filament/deposition material. When the feed gear is driven by the feed pinion of the printer, the feed gear rotates, causing the deposition material/filament to move towards the nozzle260. In designs involving a spool of filament that is rotatably mounted within the cartridge, as the feed gear is rotated, more filament is uncoiled from the spool and moved through the nozzle assembly225.

At step1835, the cartridge dispenses deposition material210through the nozzle260. That is, the deposition material is dispensed in a plastic/glass state from the nozzle onto the platform445of the printer400.

Referring next toFIG. 19, a method1900for using a three-dimensional printer according to a particular embodiment of the present invention will be described. This method1900may be performed using any of the cartridges or printers described herein (e.g., the cartridge200and printer400ofFIGS. 2 and 4, respectively.)

At step1905, a cartridge200and a three-dimensional printer400are provided. At step1910, the printer400receives a cartridge200. For example, the printer400may include a cartridge interface415. The cartridge interface may include any suitable feature that is used to help secure the cartridge to the printer e.g., a rail, a slot, a latch, etc. The user then attaches the cartridge with the printer using the cartridge interface e.g., as described in connection withFIGS. 9, 10 and 11.

At step1915, the printer400engages a heater receiving element250of the cartridge200with the heating element435. In various embodiments, the printer may extend its heating element into an opening in the heater receiving element e.g., as described in connection withFIGS. 8-14. Once the heating element435is inserted fully into the heater receiving element250, it is positioned near to or adjacent to deposition material within the nozzle assembly225of the cartridge200, thereby allowing it to heat the deposition material.

At step1920, the printer400engages a feed mechanism233in the cartridge200. In various embodiments, a feed pinion425in the printer400engages a feed gear212in the cartridge200. A motor430in the printer drives the feed pinion425, causing it to rotate. The rotation of the feed pinion is arranged to rotate the feed gear, which in turn helps move the deposition material/filament through the nozzle assembly, as previously described.

At step1925, the printer400is activated e.g., using a remote device, wireless connection or a power switch on the printer. At step1930, the printer positions the platform relative to the nozzle. During this step, any of the steps of method1500ofFIG. 15may be performed e.g., positioning/moving the platform, causing a contact to be touched, receiving a signal, etc.

At step1935, the printer400heats the deposition material in the cartridge200. As previously described, in some embodiments, the heating element435of the printer400may be a metallic tube that includes a coil/wire. The printer400runs an electrical current through the coil/wire, which causes the temperature of the heating element to rise.

At step1940, the printer400uses the cartridge200to dispense deposition material over the platform445. That is, the printer400uses its engagement with the feed mechanism4233in the cartridge200to move deposition material through the nozzle assembly225. The printer heats a portion of the deposition material that is near to or adjacent to the nozzle. Deposition material is then dispensed from the nozzle. Based on data received from a connected computing device115, the printer400continuously repositions the platform relative to the nozzle so that the desired object is formed from the dispensed deposition material.

The above application includes various methods, each with multiple operations. It should be noted that in some implementations, one or more of these operations are modified, reordered or removed. In other implementations, one or more operations are added. Thus, it should be appreciated that the methods may be adjusted as needed for various applications.

The application sometimes refers to structure that have multiple components. It should be noted, however, that not all implementations of the structure need to have all of the described components. Some implementations may have only one or some of the components, or may have fewer or more components. For example, in this application, there are references to a nozzle assembly. One description of a nozzle assembly indicates that a nozzle assembly includes at least a tube, heat sink, heater receiving element, a thermally insulating layer and a nozzle. However, in some implementations of the nozzle assembly, the nozzle assembly includes none of these elements except for the nozzle. In other implementations, one, some, all or more than these components are included in the nozzle assembly.

This application sometimes refers to Cartesian and polar coordinate printers. A Cartesian printer is a printer that is based on a Cartesian coordinate system. In various implementations, this means that the printer is controlled at least in part based on Cartesian coordinates e.g., X, Y and Z coordinates. For example, some printer designs involve identifying locations on the surface of a printing platform in terms of X and Y coordinates. The height or elevation of a printing platform and/or a nozzle may be defined using a Z coordinate. The printer then generates or obtains instructions that indicate how the platform and/or nozzle should be moved during the printing process in order to form a desired object. The printer moves these components based on the instructions. In a Cartesian printer, these movements and instructions may involve the use of the X, Y and Z coordinates.

A polar coordinate printer is a printer that is based on a polar coordinate system. In various implementations, this means that the printer is controlled based on polar coordinates e.g., an amount of rotation and a radius or distance from a center/origin point. For example, in some printer designs, locations on the surface of the platform are understood or represented in terms of distance from a single (central) point (e.g., radius) and an angle. When the printer generates or obtains instructions that indicate how the platform and/or nozzle should be moved during a printing process, the instructions are based or use polar coordinates.

Any of the methods or operations described herein for any device (e.g., the printer or cartridge) may be stored in the form of executable computer code in a non-transitory, computer readable medium. The computer code, when executed by a processor in the device, will cause the device to perform the operations.

Although only a few embodiments of the invention have been described in detail, it should be appreciated that the invention may be implemented in many other forms without departing from the spirit or scope of the invention. For example, the drawings and specification of this application described a variety of different printer and cartridge designs. It should be appreciated that any component described in one figure may include any feature of the corresponding component in another figure. Therefore, the present embodiments should be considered as illustrative and not restrictive and the invention is not limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.