Three dimensional printer system

Technologies are described for printer systems. The systems may comprise a column with a first end in operative relationship with a hopper. The systems may comprise a nozzle at a second end of the column. The nozzle may be configured to deposit melted plastic. The systems may comprise a first heating element. The first heating element may be configured to supply heat sufficient to melt plastic to the column. The systems may comprise an auger within the column. The auger may be configured to transport melted plastic from a first section of the column to the nozzle. The systems may comprise a second heating element. The second heating element may be configured to supply heat to the column to increase a temperature of melted plastic. The systems may comprise a controller. The controller may control a position of the deposited melted plastic relative to a base to form an object.

BACKGROUND

A three dimensional printer creates a three dimensional object by an additive manufacturing process in which layers of material are formed successively to create the object. Objects may be of any shape and may be created from a three dimensional model. A three dimensional printer may utilize computer control to form layers and produce the object.

SUMMARY

In some examples printer systems are described. The systems may comprise a hopper. The systems may comprise a column. The column may have a first end and a second end. The first end of the column may be in operative relationship with the hopper. The systems may comprise a nozzle at the second end of the column. The nozzle may be configured to deposit melted plastic. The systems may comprise a first heating element in thermal communication with the column. The first heating element may be configured to supply heat to a first section of the column sufficient to melt plastic within the first section of the column. The systems may comprise an auger within the column. The auger may be configured to rotate within the column to transport melted plastic from the first section of the column to the nozzle at the second end of the column. The systems may comprise a second heating element in thermal communication with the column. The second heating element may be configured to supply heat to a second section of the column to increase a temperature of melted plastic as the auger transports melted plastic to the nozzle. The systems may comprise a controller. The controller may control a position of the deposited melted plastic relative to a base to form an object on the base.

In some examples, methods for three dimensional printing an object are described. The methods may comprise receiving plastic pellets at a hopper. The methods may comprise heating the plastic pellets to produce melted plastic pellets. The methods may comprise transporting the melted plastic pellets along a column to a nozzle. The methods may comprise heating the melted plastic pellets within the column to a temperature setting. The methods may comprise positioning the melted plastic pellets in three dimensions relative to a base. The methods may comprise depositing the melted plastic pellets on the base to print the object.

In some examples, methods for three dimensional printing an orthopedic brace. The methods may comprise scanning a limb. The methods may comprise creating a three dimensional file of the scanned limb. The methods may comprise storing the three dimensional file in a memory. The methods may comprise sending the three dimensional file to a controller. The methods may comprise receiving plastic pellets at a hopper. The methods may comprise heating the plastic pellets to produce melted plastic pellets. The methods may comprise transporting the melted plastic pellets along a column to a nozzle. The methods may comprise heating the melted plastic pellets within the column to a temperature setting. The methods may comprise processing the three dimensional file to position the melted plastic pellets in three dimensions relative to a base. The methods may comprise depositing the melted plastic pellets on the base to print the orthopedic brace.

all arranged according to at least some embodiments described herein.

DETAILED DESCRIPTION

It will be understood that any compound, material or substance which is expressly or implicitly disclosed in the specification and/or recited in a claim as belonging to a group or structurally, compositionally and/or functionally related compounds, materials or substances, includes individual representatives of the group and all combinations thereof.

FIG. 1is a side perspective view illustrating a three dimensional printer system, arranged in accordance with at least some embodiments presented herein. As discussed in more detail below, a three dimensional printer system may allow a user to print an object from plastic pellets.

Three dimensional printer system100may include a hopper10, a heater30, a guide arm45, an auger50, a controller55, a gear box60, a column65, a heater70, a heater75, a heater80, a nozzle90, a base130, and fans140. Column65may include auger50and heaters30,70,75, and80. Column65may be in operative relationship with hopper10and nozzle90. Guide arm45may be in operative relationship with column65.

Hopper10may be configured to receive pellets20. Pellets20may include one or more of high density polyethylene (HDPE), low density polyethylene (LDPE), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polypropylene (PP), polystyrene (PS), acrylic, epoxy, acetal, copolymer, polyethylene terephthalate (PETG), polyactic acid (PLA), nylon, silicon, chocolate, and wax. Pellets20may include a master batch including a mixture of more than one pellet material. Pellets20may include dye pellets added to a master batch. A base of hopper10may be in operative relationship with a first end of a column65. A second end of column65may be in operative relationship with nozzle90. Heater30may be a heating element and may be in thermal communication with column65proximate to a base of hopper10. Heater30may supply heat to pellets20within column65sufficient to melt pellets20and produce melted pellets40. Heater30may heat pellets20within column65to a temperature from 45 degrees Fahrenheit to 450 degrees Fahrenheit. Heater30may completely encircle a length of column65proximate to base of hopper10and may provide even heating throughout a heated section42of column65. Auger50, located below the heated section42of column65and the heater30, may transport melted pellets40along column65from heated section42to nozzle90.

Auger50may be in mechanical communication with gear box60. Gear box50may control a torque (ft·lb) and rotations per minute (RPM) of auger50. Gear box60may control torque and RPM of auger50to increase or decrease a flow rate of melted pellets40to nozzle90. Gear box60may control torque of auger50in a range from 0 ft·lb to 100 ft·lb. Gear box60may control RPM of auger50in a range from 0 RPM to 100 RPM. Gear box60may be easily accessed and calibrated. Auger50may rotate within column65and transport melted pellets40through column65from heated section42to nozzle90at a flow rate controlled by gear box60.

A heating element67may be comprised of heater70, heater75, and heater80and may be in thermal communication with column65. Heater70may completely encircle a length of column65and may provide even heating throughout a heated section72of column65. Heater75may completely encircle a length of column65and may provide even heating throughout a heated section77of column65. Heater80may completely encircle a length of column65and may provide even heating throughout a heated section82of column65. Heated section72, heated section77, and heated section82may be sequentially located along a length of column65and heated section82may be proximate to nozzle90. Heater70, heater75, and heater80may increase a temperature of melted pellets40within column65as auger50transports melted pellets40toward nozzle90. Heater70may be set to a first temperature T1, heater75may be set to a second temperature T2, and heater80may be set to a third temperature T3, such that T3>T2>T1.

Controller55may include computer guidance control and55may include computer number control (CNC) guidance. Controller55may execute software, such as executing a file150of a three dimensional printable model of an object. File150may be created by computer-aided design (CAD), a three dimensional scanner, a digital camera and photogrammetry software, or any other software to create a three dimensional printable model of an object. File150may be scanned for errors and repaired prior to execution by controller55. File150may include a numerical control (NC) programming language, such as a G-code file. File150may include instructions related to printing of an object110.

Controller55may be in communication with control motor52. Control motor52may be in operative relationship with guide arm45. Controller55may, by controlling control motor52, control a movement/positioning of guide arm45in three dimensions relative to base103and thus control a position of column65and nozzle90relative to base130. Controller55may control motor52to position nozzle90at a position along an x-axis parallel to base130(left to right relative to base130), a y-axis perpendicular to the x-axis (front to back relative to base130), and a z-axis (up and down relative to base130). In another embodiment, nozzle90may be in a fixed position, and base130may be positioned to an x-axis, y-axis, and z-axis position relative to fixed nozzle90.

Gear box60may control RPM of auger50, to initiate and control a flow rate of melted pellets40to nozzle90. Melted pellets40may flow from nozzle90as a tube of melted pellets105. Tube of melted pellets105may be positioned by controller55. Nozzle90may be configured to deposit tube of melted pellets105to form object110on base130. Tube of melted pellets105may deposit in a layer as tube of melted pellets105is positioned by controller55. As described in more detail below, layers of tubes of melted pellets105may be deposited upon previously deposited layers of tubes of melted pellets105to form object110.

Three dimensional printer system100may be a closed system. Three dimensional printer system100may be maintained at a set temperature and humidity. Fans140may provide cooling to deposited layers of tubes of melted pellets105. Fans140may be aimed to direct a flow of air towards object110on base130. Fans140may be controlled so as to maintain a set temperature of three dimensional printer system100.

FIG. 2is a blown up side view illustrating the nozzle of a three dimensional printing system, arranged in accordance with at least some embodiments presented herein. Those components inFIG. 2that are labeled identically to components ofFIG. 1will not be described again for the purposes of clarity.

Nozzle90may be shaped so as to direct and deposit a flow of melted pellets40from auger50at a position designated by controller55and deposit a layer of tube of melted pellets105. Nozzle90may be at an angle Θ relative to vertically in line with column65. Angle Θ may be from 0 to 45 degrees from vertically in line with column65. Nozzle90may include a beveled tip95. For example, as shown inFIG. 2controller55may position tube of melted pellets105to be deposited by nozzle90to form layer115. Layer115may have a top115tand a bottom115bwhich may define a height116of layer115. As discussed in more detail below, controller55may subsequently position tube of melted pellets105to be deposited by nozzle90to form another layer of tube of melted pellets105.

FIG. 3is a blown up side view illustrating the nozzle of a three dimensional printing system, arranged in accordance with at least some embodiments presented herein. Those components inFIG. 3that are labeled identically to components ofFIGS. 1-2will not be described again for the purposes of clarity. Beveled tip95of nozzle90may allow nozzle90to be positioned at a z-axis position within a previously deposited layer of tube of melted pellets105.

For example, as shown inFIG. 3nozzle90may be positioned to deposit tube of melted pellets105to form layer120on top of previously deposited layer115. Nozzle90may be positioned such that beveled end95is at a z-axis position between top115tand bottom115bof previously deposited layer115. Nozzle90may deposit tube of melted pellets105such that tube of melted pellets105forming layer120compresses previously deposited layer115to form compressed layer117. Compressed layer117may have a top117tand a bottom117bwhich may define a height118of compressed layer117. Height118may be less than height116of previously deposited layer115. Gear box60may control torque and RPM of auger50, to control a flow rate of tube of melted pellets105and control a rate of compression of previously deposited layer115. Compression of previously deposited layer115to compressed layer117may result in better adhesion and bonding between compressed layer117and layer120and may result in a stronger structure of object110.

FIG. 4is a blown up side view illustrating the nozzle of a three dimensional printing system, arranged in accordance with at least some embodiments presented herein. Those components inFIG. 4that are labeled identically to components ofFIGS. 1-3will not be described again for the purposes of clarity.

Controller55may control guide arm45in three dimensions relative to base103and control nozzle90in three dimensions relative to base130. Controller55may control guide arm45to vibrate nozzle90along an x-axis parallel to base130(left to right relative to base130), along a y-axis perpendicular to the x-axis (front to back relative to base130), and/or along a z-axis (up and down relative to base130). Controller55may vibrate nozzle90while nozzle90deposits tube of melted pellets105to previously deposited layer115to form compressed layer117.

FIG. 5is a blown up side view illustrating a three dimensional printing system, arranged in accordance with at least some embodiments presented herein. Those components inFIG. 5that are labeled identically to components ofFIGS. 1-4will not be described again for the purposes of clarity.

In an example, three dimensional printing system200may print an orthopedic brace540for a patient510. Scanner520may scan a limb550requiring an orthopedic brace of patient510. Scanner520may utilize three dimensional photogrammetry and may take several images of limb550. Scanner520may include a three dimensional laser scanner, a camera, a tablet device, a cell phone, etc. Scanner520may be in communication with a processor530. Processor530may receive images from scanner520. Processor530may execute instructions570in a memory560to produce file580. File580may be a three dimensional file of scanned limb550and may include instructions related to printing of an orthopedic brace540based on scanned images of limb550. File580may be stored in memory560. Processor530may be in communication with controller55. Processor530may send file580to controller55. Controller55may execute file580to position nozzle90and deposit layers of tubes of melted pellets105to form an orthopedic brace540.

FIG. 6illustrates a flow diagram of an example process to produce an object utilizing a three dimensional printer system. The process inFIG. 6could be implemented using, for example, systems100and200discussed above. An example process may include one or more operations, actions, or functions as illustrated by one or more of blocks S2, S4, S6, S8, S10, S12, S14, S16, S18, and/or S20. Although illustrated as discrete blocks, various blocks may be divided into additional blocks, combined into fewer blocks, or eliminated, depending on the desired implementation.

Processing may begin at block S2, “Receive plastic pellets at a hopper.” At block S2, plastic pellets may be received at a hopper. The pellets may include one or more of high density polyethylene (HDPE), low density polyethylene (LDPE), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polypropylene (PP), polystyrene (PS), acrylic, epoxy, acetal, copolymer, polyethylene terephthalate (PETG), polyactic acid (PLA), nylon, and silicon. The pellets may include a master batch including a mixture of more than one pellet material. The pellets may include dye pellets added to a master batch.

Processing may continue from block S2to block S4, “Heat the plastic pellets to produce melted plastic pellets.” At block S4, the plastic pellets may be heated to produce melted plastic pellets. A heater may heat the plastic pellets to a temperature from 45 degrees Fahrenheit to 450 degrees Fahrenheit.

Processing may continue from block S4to block S6, “Transport the melted plastic pellets along a column to a nozzle.” At block S6, The melted plastic pellets may be transported along a column to a nozzle. An auger may transport the melted plastic pellets along the column to the nozzle. The auger may be in mechanical with a gear box. The gear box may control a torque (ft·lb) and rotations per minute (RPM) of the auger. The gear box may control torque and RPM of the auger to increase or decrease a flow rate of the melted pellets to the nozzle. The gear box may control the torque of the auger in a range from 0 ft·lb to 100 ft·lb. The gear box may control the RPM of the auger in a range from 0 RPM to 100 RPM. The gear box may be easily accessed and calibrated. The auger may rotate within the column and transport the melted pellets through the column to the nozzle at a flow rate controlled by the gear box.

Processing may continue from block S6to block S8, “Heat the melted plastic pellets within the column to a temperature setting.” At block S8, the melted plastic pellets within the column may be heated to a temperature setting. A heater may heat the melted plastic pellets to a temperature from 45 degrees Fahrenheit to 450 degrees Fahrenheit.

Processing may continue from block S8to block S10, “Position the melted plastic pellets in three dimensions relative to a base.” At block S10, the melted plastic pellets may be positioned in three dimensions relative to a base. A controller may execute software, such as executing a file of a three dimensional printable model of an object to position the melted plastic pellets. The file may be created by computer-aided design (CAD), a three dimensional scanner, a digital camera and photogrammetry software, or any other software to create a three dimensional printable model of an object. The file may be scanned for errors and repaired prior to execution by the controller. The file may include a numerical control (NC) programming language, such as a G-code file. The file may include instructions related to printing of an object. The controller may be in communication with a control motor. The control motor may be in operative relationship with a guide arm. The guide arm may be in mechanical communication with the column. The controller may, by controlling the control motor, control a movement/positioning of the guide arm in three dimensions relative to the base and thus control a position of the column and the nozzle relative to the base. The controller may control the control motor to position the nozzle at a position along an x-axis parallel to the base (left to right relative to the base), a y-axis perpendicular to the x-axis (front to back relative to the base), and a z-axis (up and down relative to the base). In another embodiment, the nozzle may be in a fixed position, and the base may be positioned to an x-axis, y-axis, and z-axis position relative to the fixed nozzle.

Processing may continue from block S10to block S12, “Deposit the melted plastic pellets on the base to print the object.” At block S12, the melted plastic pellets may be deposited on the base to print the object. The melted pellets may flow from the nozzle as a tube of melted pellets. The tube of melted pellets may be positioned on the base by the controller. The nozzle may be configured to deposit the tube of melted pellets to form the object on the base. The tube of melted pellets may deposit in a layer as the tube of melted pellets is positioned by the controller. Layers of tubes of melted pellets may be deposited upon previously deposited layers of tubes of melted pellets to form the object110.

A system in accordance with the present disclosure may provide a three dimensional printer with the capabilities to print an object from plastic pellets. A system in accordance with the present disclosure may be more cost effective than other three dimensional printers due to a lower cost of plastic pellets compared to traditional three dimensional printing plastic filament feedstock. A system in accordance with the present disclosure may have the accuracy of a traditional three dimensional printer with the versatility of an extruder. A system in accordance with the present disclosure may print objects with greater strength and in less time than other three dimensional printing systems.