SPLIT SPOOL ASSEMBLY FOR A THREE-DIMENSIONAL PRINTER

A split spool assembly for discharging filament to a three-dimensional printer is provided. The assembly includes a first spool part having a first reel collar angularly spaced from an axis and a first hub portion, which is disposed about the axis and angularly spaced from the first reel collar. The assembly further includes a second spool part having a second reel collar angularly spaced from the axis and a second hub portion, which is disposed about the axis and angularly spaced from the second reel collar. The first and second collars are spaced from one another for storing a predetermined amount of filament therebetween. The first and second hub portions are disposed about the axis and terminate at associated first and second ends, with the first and second ends being positioned adjacent to one another such that the first and second hub portions are arranged in series along the axis.

TECHNICAL FIELD

The present disclosure relates to three-dimensional (3D) printers, and more particularly to a split spool assembly for dispensing 3D filament to one or more 3D printers.

BACKGROUND

Three-dimensional printers form three dimensional objects from computer generated models. In some instances, the printers deposit a feed stock in an additive manufacturing process. The feed stock may be deposited utilizing a printer head, which draws the feedstock, such as a thermoplastic filament, from a spool contained within a cannister. The printer head may move in a three-dimensional path while heating and depositing the feedstock to form the object. For example, the printer head may deposit the feedstock in a first layer and then, either the printer head, or the support table, may be moved to form successive layers. This process may then be repeated until the object is completed.

A number of challenges arise in the printing of objects using conventional spools for three-dimensional printers. One challenge in the printing process is that the supply of filament on a spool can be quickly exhausted when, for example, the printer is utilized for printing large objects. Another challenge is that empty spools without filament may not nest with one another to efficiently utilize available storage space.

Thus, while current spools achieve their intended purpose, there is a need for a new and improved split spool assembly and methods for manufacturing the same to increase the amount of filament stored on and dispensed from the spool assembly and permit empty spool assemblies to be nested with one another for efficient packaging and storage.

SUMMARY

The present disclosure provides a split spool assembly for discharging filament to a three-dimensional printer. The split spool assembly includes a first spool part having a first reel collar angularly spaced from an axis and a first hub portion, which is disposed about the axis and angularly spaced from the first reel collar. The split spool assembly further includes a second spool part having a second reel collar angularly spaced from the axis and a second hub portion, which is disposed about the axis and angularly spaced from the second reel collar. The first and second reel collars are spaced from one another by a width for storing a predetermined amount of filament therebetween. The first and second hub portions are disposed about the axis and terminate at associated first and second ends, with the first and second ends being positioned adjacent to one another such that the first and second hub portions are arranged in series along the axis. A combined length of the first and second hub portions provides the width between the first and second reel collars for supporting the filament wound around the first and second hub portions.

The present disclosure also provides a three-dimensional printer includes an enclosure that defines a chamber. The printer further includes a work surface disposed within the chamber and a hozzle for melting and dispensing a filament within the chamber. The printer further includes one or more canisters containing a split spool assembly for storing the filament. The printer further includes a filament drive system for engaging the filament and drawing the filament from the canisters, with the hozzle receiving the filament from the filament drive system. The split spool assembly includes a first spool part having a first reel collar angularly spaced from an axis and a first hub portion, which is disposed about the axis and angularly spaced from the first reel collar. The split spool assembly further includes a second spool part having a second reel collar angularly spaced from the axis and a second hub portion, which is disposed about the axis and angularly spaced from the second reel collar. The first and second reel collars are spaced from one another by a width for storing a predetermined amount of filament therebetween. The first and second hub portions are disposed about the axis and terminate at associated first and second ends, with the first and second ends being positioned adjacent to one another such that the first and second hub portions are arranged in series along the axis. A combined length of the first and second hub portions provides the width between the first and second reel collars for supporting the filament wound around the first and second hub portions.

The present disclosure also provides a method for manufacturing a split spool assembly including first and second spool parts. The first and second spool parts have associated first and second reel collars angularly spaced from an axis and first and second hub portions disposed about the axis. The method includes placing a flat sheet metal into a stamping press and drawing the first and second hub portions from the sheet metal. The first and second reel collars are cut from the flat sheet metal, and the first and second hub portions are positioned adjacent to one another, such that the first and second hub portions are arranged in series along the axis and a combined length of the first and second hub portions provides a width between the first and second reel collars. The first and second hub portions are connected to one another, and filament is wound around the first and second hub portions.

Other features and advantages of the present disclosure will be readily appreciated, as the same becomes better understood, after reading the subsequent description taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION

Referring toFIG. 1, one example of a three-dimensional (3D) printer10includes one or more canisters12each containing a split spool assembly100(FIG. 3) for storing a filament104. The printer10further includes a filament drive system14that engages one or more filaments104from associated canisters12and draws those filaments from the same. WhileFIG. 1illustrates the filament drive system14engaging one filament104dispensed from only one cannister, it is contemplated that the filament drive system14can engage two or more filaments dispensed from any one or more canisters12. The printer10further includes an enclosure16that defines a chamber18, and the printer10includes a hozzle20for receiving the filament104from the filament drive system14, heating the filament104, and moving within an XY plane to dispense the melted filament in the chamber18. The printer10includes an XY all-linear motor system22for moving the hozzle within the XY plane to 3D print an item within the chamber18. The printer10further includes a work surface24for supporting the item and a Z-motor system (not shown) for linearly moving the work surface along the Z-axis to facilitate with 3D printing the item. However, it is contemplated that either one or both of the hozzle20and the work surface can be movable in any suitable directions for 3D printing the item. The printer10further includes a controller26electrically coupled to the filament drive system14, the XY drive system22, the hozzle20, and the Z-motor system for actuating the same to 3D print the item. It will be appreciated that the split spool assembly100(FIG. 3) can be used to dispense filament to any suitable 3D printer.

Referring toFIGS. 3 and 4, one example of a split spool assembly100is configured to rotate about an axis102for discharging the filament104(FIG. 3) from the cannister12to the filament drive system14. As best shown inFIG. 4, the split spool assembly100includes first and second spool parts106,108connected to one another. In this example, the first and second spool parts106,108are identical to one another, and each one of the first and second spool parts106,108is a single-piece aluminum sheet metal part formed from deep drawn metal stamping on the same die. However, it is contemplated that the first and second spool parts may not be identical to one another, and either one or both of the spool parts can be made of other materials formed by any suitable manufacturing process.

The first and second spool parts106,108include associated first and second reel collars110,112spaced from one another by a width W for storing a predetermined amount of filament104(FIG. 3) therebetween. For example, first and second reel collars110,112may be spaced from one another by a width W that accommodates 15 kilograms of filament on the split spool assembly. However, it is contemplated that the first and second reel collars110,112can be spaced from one another by other distances for storing more or less than 15 kg of filament therebetween. In addition, the first and second reel collars110,112are angularly spaced from the axis102. In this example, each of the first and second reel collars110,112is angularly spaced ninety (90) degrees relative to the axis102. However, it is contemplated that either one or both of the first and second reel collars110,112can be angularly spaced more or less than ninety (90) degrees relative to the axis. Each of the first and second reel collars110,112includes a plurality of apertures114,116for reducing the weight of the split spool assembly100and providing passages for a flow of air to ventilate the filament.

Referring toFIGS. 4 and 7, the first and second spool parts106,108further include associated first and second hub portions118,120, which are disposed about the axis102and angularly spaced from the associated first and second reel collars110,112. Continuing with the previous example, the first and second hub portions118,120can be drawn from the associated first and second reel collars110,112in a stamping process. The draw angle may be ninety degrees to increase the amount of filament stored on the spool assembly, as compared to a lower draw angle. However, it is contemplated that the first and second hub portions can be formed by draw angles above or less than 90 degrees. Still in other examples, the first and second hub portions can be formed from other manufacturing processes. The first and second hub portions118,120are disposed about the common axis102and terminate at associated first and second ends122,124. The first and second ends122,124are positioned adjacent to one another, such that the first and second hub portions118,120are arranged in series along the axis102. The combined length of the first and second hub portions118,120spaces the first and second reel collars from one another to provide the width (W) between the first and second reel collars for supporting filament wound around the first and second hub portions118,120.

As best shown inFIG. 7, the first and second hub portions118,120define a plurality of openings126,128or notches for providing clearance for the hub portions118,120to be drawn from the associated first and second reel collars110,112. Continuing with the previous example, the openings126,128can be configured to provide sufficient clearance for deeply drawing the first and second hub portions118,120from the associated first and second reel collars110,112, which may increase the width W between the first and second reel collars110,112and the associated capacity for storing filament104on the split spool assembly100. More specifically, as best shown inFIG. 7, the openings126,128form a saw-tooth profile119for the associated first and second hub portions118,120. Put another way, the size and number of openings may result in the first and second hub portions118,120being formed from a plurality of tabs123,125spaced from one another about the axis102. Furthermore, the openings also reduce the weight of the split spool assembly100and ventilate the filament. It will be appreciated that the split spool assembly is reusable such that new filament can be loaded and wound around the split pool assembly after the original filament on the split spool assembly has been completely dispensed from same.

With continued reference toFIG. 7, the first and second hub portions118,120terminate at one or more tip portions130,132at an end of the hub portions118,120opposite to the associated first and second reel collars110,112. In this example, the tip portions130,132extend radially inward from the associated first and second hub portions118,120. However, in other examples, one or both of the first and second spool parts can have tip portions that extend radially outward from the axis or parallel with the axis. The tip portions130of the first hub portion118are connected to the associated tip portions132of the second hub portion120, with half of the tip portions of each hub portion having threaded fasteners, such as swage nuts134, attached thereto. More specifically, each tip portion130of the first hub portion118has an interfacing surface138for engaging an associated interfacing surface140of the second hub portion120. In this example, each of the first and second hub portions118,120includes six (6) tip portions130,132, and each tip portion130,132defines a hole (not shown). Also, in this example, each tip portion130,132has a distal surface146,148opposite to the interfacing surface138,140, and half of the distal surfaces of the tip portions130,132for each hub portion118,120includes an associated one of three (3) swage nuts134mounted thereto. It is contemplated that the first and second hub portions can have more or fewer than six tip portions including more or fewer than three swage nuts or other fasteners. Furthermore, in other examples, the spool parts may not include separate threaded fasteners attached to the sheet metal, but rather the sheet metal can be pierce threaded such that the threaded fasteners are integral portions of the sheet metal.

Referring toFIGS. 7 and 8, at least one of the first and second reel collars106,108has a rolled lip peripheral edge156. This edge156can provide a smooth roller surface for feeding filament, and the rolled lip edge156can reinforce the associated reel collar. In this example, both of the first and second reel collars106,108have a rolled lip peripheral edge156. However, in other examples, it is contemplated that the only one or neither of the reel collars may have a rolled lip peripheral edge.

Referring toFIGS. 9 and 10, prior to joining the identical first and second spool parts106,108for manufacturing the split spool assembly100, two or more of the first and second spool parts106,108can be nested within one another for compact storage or shipping of the spool parts. More specifically, as best shown inFIG. 10, each of the first and second hub portions118,120has a frustoconical shape with an inner surface158facing the axis102and an outer surface160facing radially outward relative to the axis102. The inner surface158defines a socket162having an inner diameter ID that tapers from the reel collar toward the ends122,124of the associated first and second hub portions118,120, such that the stack of first and second spool parts106,108are nested within one another with the socket162of the spool part receiving the outer surface160of the adjacent spool part.

Referring toFIG. 11, a method200for manufacturing the split spool assembly100ofFIG. 2begins at block202with the step of providing a blank of sheet metal for cold forming in a stamping press machine. In this example, a roll of aluminum sheet metal can be fed into the stamping press machine, with a stamping die configured to form the first and second spool parts nested with one another on the sheet metal. It is contemplated that any other suitable manufacturing process may be used to manufacture the split spool assembly.

At block204, the stamping press machine cuts the notches or openings126,128in the sheet metal that are configured to provide clearance for the first and second hub portions118,120to be drawn from the first and second reel collars110,112. In addition, the stamping press machine cuts the holes126,128in the remaining sheet metal to form apertures for ventilating the filament wound around the first and second hub portions118,120between the first and second reel collars110,112. Also, the press stamping machine may pierce the sheet metal to form the holes142,144in the tip portions130,132.

At block206, the stamping press machine draws the first and second hub portions118,120from the sheet metal. In this example, the first and second hub portions118,120are deeply drawn from the sheet metal by a depth greater than a diameter of the associated first and second reel collars110,112. However, it is contemplated that the first and second hub portions can be drawn from the sheet metal by a depth equal to or less than the diameter of the associated first and second reel collars.

At block208, the stamping press machine forms the tip portions130,132at the ends of the associated first and second hub portions118,120. The stamping press machine may form the tip portions130,132to extend ninety (90) degrees from the first and second hub portions and radially inward toward the axis102. However, it is contemplated that the tip portions can be formed to extend radially outward from the first and second hub portions or parallel with axis102.

At block210, the first and second spool parts are cut out and separated from the sheet metal.

At block212, nuts are attached to half of the tip portions, on a side of the tip portions opposite to the other spool part. In this example, each of the first and second spool parts is formed with six (6) tip portions, and three (3) nuts are attached to every other tip portion by a swaging process. However, it is contemplated other fasteners can be mounted to the tip portions by other suitable manufacturing processes.

At block214, the first and second spool parts106,108are positioned such that the tip portions130,132of the first and second spool parts are engaging one another while positioning only one swage nut at each pair of engaged tip portions.

At block216, the first and second hub portions are connected to one another. Continuing with the previous example, a plurality of threaded fasteners150,152are applied to the tip portions130,132and the swage nuts134,136for attaching the first and second spool parts106,108to one another. In this example, three (3) screws150are inserted into holes142of the first spool part to threadably engage the three (3) associated swage nuts136attached to the second spool part108, and three (3) other screws152are inserted into holes144of the second spool part108to threadably engage the three (3) associated swage nuts134attached to the first spool part106.

The description of the present disclosure is merely exemplary in nature and variations that do not depart from the general sense of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.