Patent Description:
Three-dimensional (3D) printing, also referred to as additive manufacturing, has experienced a technological explosion in the last several years. This increased interest is related to the ability of 3D printing to easily manufacture a wide variety of objects from common computer-aided design (CAD) files. In 3D printing, a composition is laid down in successive layers of material to build a structure. These layers may be produced, for example, from liquid, powder, paper, or sheet material.

In some conventional configurations, a 3D printing system utilizes a thermoplastic material. The 3D printing system extrudes the thermoplastic material through a heated nozzle on to a platform. Using instructions derived from a CAD file, the system moves the nozzle with respect to the platform, successively building up layers of thermoplastic material to form a 3D object. After being extruded from the nozzle, the thermoplastic material cools. The resulting 3D object is thus made of layers of thermoplastic material that have been extruded in a heated form and layered on top of each other. <CIT> relates to a method for creating a three-dimensional solid freeform fabrication object including spreading a reactive powder on a substrate, selectively dispensing a core binder in the reactive powder to form a core material, and selectively dispensing a shell binder in the reactive powder to form a shell on the core material. <CIT> relates to a three-dimensional (3D) printing system for forming 3D objects.

The present invention relates to a computer system (<NUM>) for part production using flow infill design, comprising: one or more processors (<NUM>); and one or more computer-readable media (<NUM>) having stored thereon executable instructions that when executed by the one or more processors (<NUM>) configure the computer system (<NUM>) to perform at least the following: receive a computer-aided design (CAD) file that describes physical dimensions of a target object (<NUM>); identify a physical boundary portion (<NUM>) of the target object within the CAD file, wherein the physical boundary portion (<NUM>) comprises a portion of the target object that is configured to enclose a coreactive infill material (<NUM>); generate a first tool path to additively manufacture the physical boundary portion (<NUM>); send instructions to a dispenser (<NUM>, <NUM>) that cause the dispenser (<NUM>, <NUM>) to implement the first tool path while dispensing a boundary material; and generate a command to dispense the coreactive infill material (<NUM>) within the physical boundary portion (<NUM>), wherein the coreactive infill material (<NUM>) chemically bonds with the boundary material.

Moreover, the present invention relates to a method (<NUM>) for part production using flow infill design, comprising when executed by one or more processors (<NUM>): receiving a computer-aided design (CAD) file (<NUM>) that describes physical dimensions of a target object (<NUM>); identifying a physical boundary portion (<NUM>) of the target object (<NUM>) within the CAD file, wherein the physical boundary portion (<NUM>) comprises a portion of the target object (<NUM>) that is configured to enclose a coreactive infill material (<NUM>); generating a first tool path to additively manufacture the physical boundary portion (<NUM>); sending instructions to a dispenser (<NUM>, <NUM>) that cause the dispenser (<NUM>, <NUM>) to implement the first tool path while dispensing a boundary material; and generating a command to dispense the coreactive infill material (<NUM>) within the physical boundary portion (<NUM>), wherein the coreactive infill material (<NUM>) chemically bonds with the boundary material.

Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows.

The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.

In order to describe the manner in which the above recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific examples thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only typical examples of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:.

The present invention extends to systems, methods, and apparatuses for rapid object production using flow infill design. The systems, methods, and apparatuses operate through the deposition of coreactive materials as infill during the creation of a target object. As used here, a "target object" may refer to a portion of a physical object or a complete physical object that is being, at least in part, additively manufactured by the systems, method, and/or apparatuses described here. Additionally, as used herein coreactive materials include thermoset materials.

Additive manufacturing using coreactive components has several advantages compared to alternative additive manufacturing methods. As used herein, "additive manufacturing" refers to the use of computer-aided design (through user generated files or 3D object scanners) to cause an additive manufacturing apparatus to deposit material, layer upon layer, in precise geometric shapes. Additive manufacturing using coreactive components can create stronger parts because the materials forming successive layers can be coreacted to form covalent bonds between the layers. Also, because the components have a low viscosity when mixed, higher filler content can be used. The higher filler content can be used to modify the mechanical and/or electrical properties of the materials and the built object. Coreactive components can extend the chemistries used in additively manufactured parts to provide improved properties such as solvent resistance and thermal resistance.

Additionally, the ability to use a computer system to control the use of coreactive components within an additive manufacturing environment provides several advantages. For example, the computer system is able to dynamically control and adjust the flow rates and tool paths of the coreactive components in ways that produce desired physical attributes of the resulting material. Such adjustments and control provide unique advantages within additive manufacturing.

The use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, the use of "or" means "and/or" unless specifically stated otherwise, even though "and/or" may be explicitly used in certain instances.

The term "polymer" is meant to include prepolymer, homopolymer, copolymer, and oligomer.

Embodiments of the present disclosure are directed to the production of structural objects using 3D printing. A 3D object may be produced by forming successive portions or layers of an object by depositing at least two coreactive components onto a substrate and thereafter depositing additional portions or layers of the object over the underlying deposited portion or layer. Layers are successively deposited to build the 3D printed object. The coreactive components can be mixed and then deposited or can be deposited separately. When deposited separately, the components can be deposited simultaneously, sequentially, or both simultaneously and sequentially.

Deposition and similar terms refer to the application of a printing material comprising a coreactiveting or coreactive composition and/or its reactive components onto a substrate (for a first portion of the object) or onto previously deposited portions or layers of the object. Each coreactive component may include monomers, prepolymers, adducts, polymers, and/or crosslinking agents, which can chemically react with the constituents of the other coreactive component.

The at least two coreactive components may be mixed together and subsequently deposited as a mixture of coreactive components that react to form portions of the object. For example, the two coreactive components may be mixed together and deposited as a mixture of coreactive components that react to form the coreactiveting composition by delivery of at least two separate streams of the coreactive components into a mixing apparatus such as a static mixer to produce a single stream that is then deposited. The coreactive components may be at least partially reacted by the time a composition comprising the reaction mixture is deposited. The deposited reaction mixture may react at least in part after deposition and may also react with previously deposited portions and/or subsequently deposited portions of the object such as underlying layers or overlying layers of the object.

Alternatively, the two coreactive components may be deposited separately from each other to react upon deposition to form the portions of the object. For example, the two coreactive components may be deposited separately such as by using an inkjet printing system whereby the coreactive components are deposited overlying each other and/or adjacent to each other in sufficient proximity so the two reactive components may react to form the portions of the object. As another example, in an extrusion, rather than being homogeneous, a cross-sectional profile of the extrusion may be inhomogeneous such that different portions of the cross-sectional profile may have one of the two coreactive components and/or may contain a mixture of the two coreactive components in a different molar and/or equivalents ratio.

Furthermore, throughout a 3D-printed object, different parts of the object may be formed using different proportions of the two coreactive components such that different parts of an object may be characterized by different material properties. For example, some parts of an object may be rigid and other parts of an object may be flexible.

It will be appreciated that the viscosity, reaction rate, and other properties of the coreactive components may be adjusted to control the flow of the coreactive components and/or the coreactiveting compositions such that the deposited portions and/or the object achieves and retains a desired structural integrity following deposition. The viscosity of the coreactive components may be adjusted by the inclusion of a solvent, or the coreactive components may be substantially free of a solvent or completely free of a solvent. The viscosity of the coreactive components may be adjusted by the inclusion of a filler, or the coreactive components may be substantially free of a filler or completely free of a filler. The viscosity of the coreactive components may be adjusted by using components having lower or higher molecular weight. For example, a coreactive component may comprise a prepolymer, a monomer, or a combination of a prepolymer and a monomer. The viscosity of the coreactive components may be adjusted by changing the deposition temperature. The coreactive components may have a viscosity and temperature profile that may be adjusted for the particular deposition method used, such as mixing prior to deposition and/or ink jetting. The viscosity may be affected by the composition of the coreactive components themselves and/or may be controlled by the inclusion of rheology modifiers as described herein.

It can be desirable that the viscosity and/or the reaction rate be such that following deposition of the coreactive components the composition retains an intended shape. For example, if the viscosity is too low and/or the reaction rate is too slow a deposited composition may flow in a way the compromises the desired shape of the finished object. Similarly, if the viscosity is too high and/or the reaction rate is too fast, the desired shape may be compromised.

Turning now to the figures, <FIG> illustrates a system for rapid object production using flow infill design. The depicted system comprises a 3D printer <NUM> in communication with a computer system <NUM>. While depicted as a physically separate component, the computer system <NUM> may also be wholly integrated within the 3D printer <NUM>, distributed between multiple different electronic devices (including a cloud computing environment), or otherwise integrated with the 3D printer <NUM>. As used herein, a "3D printer" refers to any device capable of additive manufacture using computer-generated data files. Such computer-generated data files herein are referred to as "CAD files.

The 3D printer <NUM> is depicted with a target object <NUM> in the form of a block. The block comprises a square shaped outline that is constructed by the 3D printer <NUM> using, at least in part, coreactive components. The 3D printer <NUM> comprises a dispenser <NUM> that is attached to a movement mechanism <NUM>. As used herein, a "dispenser" may comprise a dynamic nozzle, a static nozzle, injection device, a pouring device, a dispensing device, an extrusion device, a sprayer device, or any other device capable of providing a controlled flow of coreactive components. Additionally, the movement mechanism <NUM> is depicted as comprising the dispenser <NUM> attached within a track <NUM> that is moveable in an X-axis direction along an arm and another set of tracks <NUM> in which the arm is able to move in a Y-axis direction. One will appreciate, however, that this configuration is provided only for the sake of example and explanation. In additional or alternative configurations, the movement mechanism <NUM> may comprise any system that is capable of controlling a position of the dispenser <NUM> with respect to a target object <NUM>, including, but not limited to a system that causes the target object <NUM> to move with respect to the dispenser <NUM>.

As depicted, in some configurations, the 3D printer <NUM> comprises multiple dispensers <NUM>, <NUM>. The multiple dispensers may be used interchangeably or may comprise unique attributes and uses. For example, dispenser <NUM> may be utilized for additive manufacturing using coreactive components within a material, while dispenser <NUM> may be used for flowing coreactive infill materials into the target object <NUM>. Possible combined usages of these different dispensers <NUM>, <NUM> will be described in greater detail below.

<FIG> illustrates a schematic of a computer system <NUM> for rapid object production using flow infill design. The computer system <NUM> is shown as being in communication with a 3D printer <NUM>. Additionally, various modules, or units, of a flow infill design software <NUM> are depicted as being executed by the computer system <NUM>. In particular, the flow infill design software <NUM> is depicted as comprising a CAD processing unit <NUM>, a tool path generation unit <NUM>, a flow rate processing unit <NUM>, a material database <NUM>, and a dispenser control unit <NUM>.

As used herein, a "module" comprises computer executable code and/or computer hardware that performs a particular function. One of skill in the art will appreciate that the distinction between different modules is at least in part arbitrary and that modules may be otherwise combined and divided and still remain within the scope of the present disclosure. As such, the description of a component as being a "module" is provided only for the sake of clarity and explanation and should not be interpreted to indicate that any particular structure of computer executable code and/or computer hardware is required, unless expressly stated otherwise. In this description, the terms "unit", "component", "agent", "manager", "service", "engine", "virtual machine" or the like may also similarly be used.

The computer system <NUM> also comprises one or more processors <NUM> and one or more computer-storage media <NUM> having stored thereon executable instructions that when executed by the one or more processors <NUM> configure the computer system <NUM> to perform various acts. For example, the computer system <NUM> is configured to receive a computer-aided design (CAD) file that describes physical dimensions of a target object <NUM>. In the depicted example, the CAD processing unit <NUM> reads the CAD file and identifies physical dimensions for a block. The CAD file may also comprise instructions relating to the type of material and/or desired characteristics of the material that is to be used to create the block.

The computer system <NUM> is also configured to identify a physical boundary portion of the target object <NUM> within the CAD file. As used herein, the "physical boundary portion" comprises a portion of the target object that encloses coreactive infill material. As used herein, "coreactive infill material" comprises any material that is flowed into a physical boundary portion of the target object <NUM>. Additionally, as used herein, "flow" or "flowed" refers to the physical deposit of the coreactive infill material into the target object <NUM>. For example, <FIG> illustrates a physical boundary portion <NUM> of the example target object <NUM> for manufacture. <FIG> illustrates the example target object <NUM> for manufacture with the coreactive infill material <NUM> deposited within the physical boundary portion <NUM>. In the depicted example, the physical boundary portion <NUM> comprises the outer edges of the block. In some examples, however, a physical boundary portion <NUM> may not necessarily comprise the outermost edges of the target object <NUM>. For instance, a target object <NUM> may comprise multiple physical boundary portions that each define a different area that encloses coreactive infill material <NUM>.

In the depicted example, the physical boundary portion <NUM> may comprise a coreactive material, a thermoplastic material, or any other material capable of additive manufacturing with a 3D printer <NUM>. The same 3D printer <NUM> may be used for both the creation of the physical boundary portion <NUM> and the dispensing of the infill within the physical boundary portion <NUM>. In such a case, the CAD processing unit <NUM> may already be aware of the identity and relative location of the physical boundary portion <NUM> within the 3D printer <NUM> because the 3D printer itself created the physical boundary portion <NUM>.

Once CAD processing unit <NUM> has identified the physical boundary portion <NUM>, the tool path generation unit <NUM> generates a first tool path to additively manufacture the physical boundary portion <NUM>. As used herein, a "tool path" refers to the path and speed of the dispenser <NUM> as it manufactures the target object <NUM>. The tool path generation unit <NUM> generates the first tool path such that the coreactive material is dispensed from the dispenser <NUM> at a rate and along a path that will create the physical boundary portion <NUM>.

In some circumstances, the first tool path may require the dispenser <NUM> to layer coreactive material in layers on top of itself. The flow rate processing unit <NUM> and dispenser control unit <NUM> calculate a target flowrate to ensure that the coreactive material properly bonds between the different layers. Such calculations may account for the reactive time of the coreactive material such that the layers are placed on top of each other before lower layers have time to fully cure. As such, the generation of the first tool path may be based, at least in part, upon the target flow rate. As explained above, such information relating to the amount of time that different coreactive components remain reactive is provided by the material database <NUM>.

The flow rate processing unit <NUM> may calculate a target flow rate to create the physical boundary portion <NUM> with the coreactive material. As used herein, the "flow rate" comprises the rate at which one or more components of the material are dispensed from a dispenser <NUM>, <NUM>. The flow rate may be controllable on a per-component basis. For example, the tool path generation unit <NUM> comprises a flow rate processing unit <NUM> that determines and controls the target flow rate for dispensing coreactive material to create the physical boundary portion <NUM> and to dispense infill coreactive material within the physical boundary portion <NUM>.

The flow rate processing unit <NUM> may be configured to manipulate the flow rate of the coreactive material by changing properties of the coreactive components within the coreactive material for the physical boundary portion <NUM> and/or for the infill portion. It will be appreciated that the viscosity, reaction rate, and other properties of the coreactive components may be adjusted to control the flow of the coreactive components and/or the thermosetting compositions such that the deposited portions and/or the object achieves and retains a desired structural integrity following deposition. The viscosity of the coreactive components may be adjusted by the inclusion of a solvent, or the coreactive components may be substantially free of a solvent or completely free of a solvent. The viscosity of the coreactive components may be adjusted by the inclusion of a filler, or the coreactive components may be substantially free of a filler or completely free of a filler. The viscosity of the coreactive components may be adjusted by using components having lower or higher molecular weight. For example, a coreactive component may comprise a prepolymer, a monomer, or a combination of a prepolymer and a monomer. The viscosity of the coreactive components may be adjusted by changing the deposition temperature. The coreactive components may have a viscosity and temperature profile that may be adjusted for the particular deposition method used, such as mixing prior to deposition and/or ink jetting. The viscosity may be affected by the composition of the coreactive components themselves and/or may be controlled by the inclusion of rheology modifiers as described herein.

For example, the coreactive components that are deposited together may each have a viscosity at <NUM>° C. and a shear rate at <NUM>-<NUM> from <NUM>,<NUM> centipoise (cP) to <NUM>,<NUM>,<NUM> cP, from <NUM>,<NUM> cP to <NUM>,<NUM>,<NUM> cP, or from <NUM>,<NUM> cP to <NUM>,<NUM>,<NUM> cP. The coreactive components that are deposited together may each have a viscosity at <NUM>° C. and a shear rate at <NUM>,<NUM>-<NUM> from <NUM> centipoise (cP) to <NUM>,<NUM> cP, from <NUM> cP to <NUM>,<NUM> cP, or from <NUM> to <NUM>,<NUM> cP. Viscosity values can be measured using an Anton Paar MCR <NUM> or <NUM> rheometer with a gap from <NUM> to <NUM>.

Depending upon the desired properties, an infill material and a boundary material may comprise different viscosities. For example, a boundary material may comprise a higher viscosity than an infill material, such that the boundary material holds its form, while the infill material easily flows to fill a physical boundary portions defined by the boundary material. For example, an infill material may comprise a viscosity between <NUM> cP to <NUM> cP and a boundary material may comprise a viscosity between <NUM> cP to <NUM> cP. Additionally or alternatively, an infill material may comprise a viscosity between <NUM> cP to <NUM> cP and a boundary material may comprise a viscosity between <NUM> cP to <NUM> cP. Additionally or alternatively, an infill material may comprise a viscosity between <NUM> cP to <NUM> cP and a boundary material may comprise a viscosity between <NUM> cP to <NUM> cP.

Additionally or alternatively, the dispenser control unit <NUM> may adjust the characteristics of the 3D printer <NUM> in order to achieve a desired flow rate. For example, the dispenser control unit <NUM> may cause the dispenser <NUM> to travel faster or slower in order to achieve the desired deposition rate, viscosity, and/or reaction rate. Similarly, the dispenser control unit <NUM> may cause the dispenser <NUM> to dispense the coreactive material at higher or lower rates based upon a desired flow rate. As such, the flow rate processing unit <NUM> may adjust the properties of the coreactive components within the material and/or the dispenser control unit <NUM> may adjust the mechanical operation of the 3D printer <NUM> in order to achieve a desired flowrate.

In some configurations, the 3D printer <NUM> may be capable of utilizing multiple different types of material to manufacture the target object <NUM>. These different materials may comprise different combination of coreactive components. As such, the tool path generation unit <NUM> may receive an indication of a single material or set of materials to be used as the coreactive infill material <NUM> and/or the material for the physical boundary portion <NUM> to create the target object <NUM>. In some cases, the 3D printer <NUM> is preconfigured to use only a single set of coreactive components within a single material type for all additive manufacturing.

Upon receiving the indication of the material, the tool path generation unit <NUM> accesses from a material database <NUM> characteristics of the material. In some cases, the indication of the material comprises a specific mixture coreactive components. The characteristics of the material comprise a viscosity of the material and/or various other attributes relating to the reactivity of the material. Using the information from the material database <NUM> and the processes described above, the tool path generation unit <NUM> determines the target flow rate using characteristics of the material.

In some cases, the tool path generation unit <NUM> may receive the indication of the material to be used for the coreactive infill material <NUM> based upon characteristics of the material that was used to create the physical boundary portion <NUM>. For example, the physical boundary portion <NUM> may comprise a material that has specific bonding characteristics. The computer system <NUM> may identify those bonding characteristics and communicate an indication of a material to the tool path generation unit <NUM> based upon those characteristics.

For instance, the physical boundary portion <NUM> may comprise a thermoplastic material. The computer system <NUM> may determine that a specific combination of coreactive components within a coreactive infill material <NUM> will create the strongest bond with the thermoplastic material. The computer system <NUM> communicates an indication of that material to the tool path generation unit <NUM> for generation of an appropriate tool path. Alternatively, the computer system <NUM> may determine that a particular combination of coreactive components within a coreactive infill material <NUM> will be corrosive to the thermoplastic material, and thus avoid that particular combination.

Similarly, the physical boundary portion <NUM> may comprise coreactive components within the boundary material. The tool path generation unit <NUM> may identify a particular set of coreactive components to include within the coreactive infill material <NUM> in order to create desired covalent bonding between the physical boundary portion <NUM> and the coreactive infill material <NUM>. In some cases, an end user may desire specific performance attributes of the physical boundary portion <NUM> and the coreactive infill material <NUM>. Further, the desired attributes may not be the same for the physical boundary portion <NUM> and the coreactive infill material <NUM>. In such a case, the user may provide the desired coreactive components for each material and/or the tool path generation unit <NUM> may identify the desired coreactive components for the materials.

Additionally, in some configurations, the coreactive components may utilize an external stimulus, such as UV light during the reaction process. In such cases, the 3D printer <NUM> may comprise a UV light source that controllable by the computer system <NUM>. The 3D printer <NUM> may be configurable to dispense the coreactive material and cure the material with a UV light source. Various other stimuli may be similarly implemented by the computer system <NUM> such that the stimuli are applied to the coreactive infill material during and/or after the dispensing of the coreactive infill material within the physical boundary portion <NUM>.

Additionally, the dispenser control unit <NUM> may also be configured to allow the dispenser <NUM>, <NUM> to coast during the first tool path. As used herein, "coast" refers to the ability of the dispenser <NUM> to continue along a tool path (e.g., the first tool path) while continuing to dispense coreactive material despite the 3D printer <NUM> no longer actively causing coreactive material to flow into the dispenser <NUM>. The ability to coast is caused, at least in part, due to coreactive material that is within the dispenser <NUM> and portion of the 3D printer between the dispenser <NUM> and a holding container for the coreactive material. As such, when implementing the first tool path, the dispenser may dispense unwanted, excess coreactive material if it is not allowed to coast and drain the coreactive material within the system during the first tool path. Accordingly, the generation of the first tool path may comprise a portion where the dispenser is allowed to coast and continue to extrude remaining material that is within the dispenser.

Once the first tool path has been generated, the computer system <NUM> sends instructions to a dispenser <NUM>, <NUM> that cause the dispenser <NUM> to implement the first tool path while flowing the boundary material to create the physical boundary portion <NUM>. The boundary material may comprise coreactive components that are flowed in the form of the desired physical boundary portion <NUM> as directed by the first tool path.

The computer system <NUM> also generates a command to dispense the coreactive infill material <NUM> within the physical boundary portion <NUM>. The command may comprise a command to an automated dispensing system or may comprise a command that is configured to cause a user interface to display an indication to pour the coreactive infill material within the physical boundary portion (such as the interface shown in <FIG>) to instruct a user to dispense the coreactive infill material <NUM> within the physical boundary portion <NUM>. As used herein, an "automated dispensing system" comprises any system that is capable of receiving electronic instructions to flow the coreactive infill material <NUM> within the physical boundary portion <NUM> and then to actuate an electric-mechanical motor to cause the coreactive infill material <NUM> to flow.

In some examples, the tool path generation unit <NUM> generates a command to dispense the coreactive infill material <NUM> within the physical boundary portion <NUM> by generating a second tool path to additively manufacture an infill portion that is located at least partly within the physical boundary portion <NUM>. The tool path generation unit <NUM> sends instructions to the computer system <NUM> in communication with the dispenser <NUM> that cause the dispenser to implement the second tool path while flowing coreactive infill material <NUM> to create the infill portion. Additionally or alternatively, the tool path generation unit <NUM> sends instructions to a different dispenser <NUM> that implements the second tool path while flowing coreactive infill material <NUM> to create the infill portion. As such, the automated dispensing system may comprise a 3D printer <NUM>, a particular dispenser <NUM> in a 3D printer <NUM>, or any number of other systems that are capable of flowing the coreactive infill material <NUM>.

For example, <FIG> illustrates a flow of coreactive infill material <NUM> into the physical boundary portion <NUM> of the example target object <NUM>. The depicted example, the coreactive infill material <NUM> is being poured from a container <NUM> into the physical boundary portion <NUM>. The container <NUM> may be poured by hand or may comprise a portion of a mechanical machine that is configured to pour the contents of the container <NUM> on command. The coreactive infill material <NUM> may be premeasured such that the volume of material within the container <NUM> matches a desired volume.

Additionally, the contents of the container <NUM> may be poured at substantially a single area within the physical boundary portion <NUM>. The viscosity of the coreactive infill material <NUM> may cause the material to spread out and completely fill the desired area. Additionally or alternatively, the computer system <NUM> may provide a timer during which time the coreactive infill material must be poured into the physical boundary portion <NUM>. The timer may be based upon the amount of time before the material in the physical boundary portion <NUM> cures. It may be desirable for the coreactive infill material <NUM> to be poured before that time to better enable the coreactive components in the coreactive infill material <NUM> to chemically bond with the coreactive materials in the physical boundary portion <NUM>.

<FIG> illustrates another flow of coreactive infill material <NUM> into the physical boundary portion <NUM> of the example target object <NUM>. In this depicted example, the coreactive infill material <NUM> is being sprayed into the physical boundary portion <NUM> within a sprayer <NUM>. The sprayer <NUM> may be hand operated or may be automated such that the sprayer <NUM> comprises a portion of a mechanical machine that is configured to spray the coreactive infill material <NUM> on command. The sprayer <NUM> may comprise a sensor that indicates the amount of coreactive infill material <NUM> that has been sprayed, such that the sprayer <NUM> is able to flow the correct amount of coreactive infill material <NUM> into the physical boundary portion <NUM>.

Additionally, the sprayer <NUM> may spray the coreactive infill material <NUM> at substantially a single area within the physical boundary portion <NUM>. The viscosity of the coreactive infill material <NUM> may cause the material to spread out and completely fill the desired area. Additionally or alternatively, the computer system <NUM> may provide a timer during which time the coreactive infill material must be sprayed into the physical boundary portion <NUM>. The timer may be based upon the amount of time before the material in the physical boundary portion <NUM> cures. It may be desirable for the coreactive infill material <NUM> to be sprayed before that time to better enable the coreactive components in the coreactive infill material <NUM> to chemically bond with the coreactive materials in the physical boundary portion <NUM>.

While <FIG> provide two specific examples for flowing coreactive infill material <NUM> into the physical boundary portion <NUM>, one will appreciate that these are provided for the sake of example and explanation.

<FIG> illustrates a 3D printer <NUM> being used for rapid object production using flow infill design. In the depicted example, the 3D printer <NUM> is additively manufacturing the physical boundary portion <NUM> with a first dispenser <NUM> and concurrently flowing coreactive infill material <NUM> into the physical boundary portion <NUM> from a second dispenser <NUM>. As such, in some examples, the 3D printer <NUM> may be configured to operate two separate dispensers concurrently where one dispenser additively manufactures a physical boundary portion <NUM> and the other dispenser flows coreactive infill material <NUM> into the physical boundary portion <NUM>.

In order to properly construct the desired target object <NUM>, the computer system <NUM> calculate a viscosity of the coreactive infill material with its associated coreactive components. The computer system <NUM> may also calculate the speed at which the coreactive infill material would fill the physical boundary portion <NUM>. Using this information, the computer system <NUM> calculates the amount of physical boundary portion <NUM> that must be created before the second dispenser <NUM> begins to flow the coreactive infill material <NUM> into the physical boundary portion <NUM>. One will appreciate that failure to wait until enough of the physical boundary portion <NUM> is constructed before flowing the coreactive infill material <NUM> may cause the coreactive infill material <NUM> to run outside of the desired target object <NUM>. In various configurations, the second dispenser <NUM> in <FIG> may comprise a dynamic nozzle, a static nozzle, injection device, a pouring device, a dispensing device, an extrusion device, a sprayer device, or any other device capable of providing a controlled flow of coreactive components.

Returning to <FIG>, which illustrates the completed target object <NUM> with the coreactive infill material <NUM> fully in place. The use of coreactive components to create the coreactive infill material can result in several desirable properties. For example, the coreactive infill material may be covalently bonded to the physical boundary portion <NUM> instead of the physical adhesion bonds that are often found in thermoplastic printing. Additionally, the results bonds within the coreactive infill material may be water tight and/or air tight.

In addition to or alternative to the above, the physical boundary portion <NUM> may be constructed through an additive manufacturing process using coreactive components, thermoplastic materials, and/or any other additive manufacturing. In some cases, the coreactive infill material <NUM> and the boundary material comprise the same composition. For example, the physical boundary portion <NUM> may be created from the same coreactive components as the coreactive infill material <NUM>. Alternatively, the physical boundary portion <NUM> may comprise different coreactive components than the coreactive infill material <NUM>.

Additionally, as depicted in <FIG>, the 3D printer <NUM> may comprise multiple separate dispensers <NUM>, <NUM>. The dispensers <NUM>, <NUM> may be used for different types of materials, such as a dispenser for different types of coreactive materials. For example, the dispensers may dispense different coreactive components at particular flow rates in order to produce a final coreactive material that comprises a target volume mix ratio. One will appreciate, though, that similar control of the coreactive components in a material to achieve a target volume mix ratio may be practiced with a single dispenser <NUM>. For instance, the 3D printer <NUM> may comprise a mixing apparatus that dynamically mixes coreactive components from different containers at a desired rate.

As stated above, the coreactive infill material <NUM> may comprise a mixture of two different materials, such as different reactive components. Additionally, the two different materials within the coreactive infill material <NUM> may be dispensed as a gradient. For example, two particular coreactive components within the coreactive infill material <NUM> may provide different properties based upon the volume mix ratio of the two coreactive components. As an example, the volume mix ratio of the two particular coreactive components may impact the flexibility of the resulting coreactive infill material. As such, the tool path generation unit <NUM> can calculate a volume mix ratio of components within the coreactive infill material <NUM> that changes as the coreactive infill material <NUM> is flowed into the physical boundary portion <NUM>.

<FIG> shows a flowchart of steps in a method <NUM> for rapid object production using flow infill design. The depicted method <NUM> includes an act <NUM> of receiving a CAD file. Act <NUM> comprises receiving, at one or more processors, a computer-aided design (CAD) file that describes physical dimensions of a target object. For example, as depicted and described with respect to <FIG>, the CAD processing unit <NUM> receives a CAD file of a target object <NUM>.

Method <NUM> also includes an act <NUM> of identifying a physical boundary within the CAD file. Act <NUM> comprises identifying, with the one or more processors, a physical boundary portion of the target object within the CAD file, wherein the physical boundary portion comprises a portion of the target object that encloses a coreactive infill material. For example, as depicted and described with respect to <FIG>, <FIG>, and <FIG>, the CAD processing unit <NUM> is configured to identify a physical boundary portion <NUM> of the target object <NUM>.

Additionally, method <NUM> includes an act <NUM> of generating a first tool path. Act <NUM> comprises generating a first tool path to additively manufacture the physical boundary portion <NUM>. For example, as depicted and described with respect to <FIG>, the tool path generation unit <NUM> generates a first tool path that is configured to create the physical boundary portion <NUM>.

Further, method <NUM> includes an act <NUM> of causing a dispenser to implement the tool path. Act <NUM> comprises sending instructions to a computer system <NUM> in communication with a dispenser <NUM> that cause the dispenser <NUM> to implement the first tool path while dispensing a boundary material. For example, as depicted in <FIG> and <FIG>, a dispenser <NUM> in the 3D printer <NUM> additively manufactures the physical boundary portion <NUM>.

Further still, method <NUM> includes an act <NUM> of generating a dispense command to dispense coreactive infill material. Act <NUM> comprises generating a command to dispense the coreactive infill material <NUM> within the physical boundary portion <NUM>. For example, as depicted and described with respect to <FIG>, and <FIG>, the computer system <NUM> communicates instructions to an electric mechanical apparatus or to an end user that indicates a command to flow coreactive infill material <NUM> into the physical boundary portion <NUM>.

The present invention may comprise or utilize a special-purpose or general-purpose computer system that includes computer hardware, such as, for example, one or more processors and system memory, as discussed in greater detail below. Such computer-readable media can be any available media that can be accessed by a general-purpose or special-purpose computer system. Computer-readable media that store computer-executable instructions and/or data structures are computer storage media. Computer-readable media that carry computer-executable instructions and/or data structures are transmission media. Thus, by way of example, and not limitation, embodiments of the invention can comprise at least two distinctly different kinds of computer-readable media: computer storage media and transmission media.

Computer storage media are physical storage media that store computer-executable instructions and/or data structures. Physical storage media include computer hardware, such as RAM, ROM, EEPROM, solid state drives ("SSDs"), flash memory, phase-change memory ("PCM"), optical disk storage, magnetic disk storage or other magnetic storage devices, or any other hardware storage device(s) which can be used to store program code in the form of computer-executable instructions or data structures, which can be accessed and executed by a general-purpose or special-purpose computer system to implement the disclosed functionality of the invention.

Further, upon reaching various computer system components, program code in the form of computer-executable instructions or data structures can be transferred automatically from transmission media to computer storage media (or vice versa). For example, computer-executable instructions or data structures received over a network or data link can be buffered in RAM within a network interface module (e.g., a "NIC"), and then eventually transferred to computer system RAM and/or to less volatile computer storage media at a computer system.

Those skilled in the art will appreciate that the invention may be practiced in network computing environments with many types of computer system configurations, including, personal computers, desktop computers, laptop computers, message processors, hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, mobile telephones, PDAs, tablets, pagers, routers, switches, and the like. As such, in a distributed system environment, a computer system may include a plurality of constituent computer systems.

Those skilled in the art will also appreciate that the invention may be practiced in a cloud-computing environment.

A cloud-computing model can be composed of various characteristics, such as on-demand self-service, broad network access, resource pooling, rapid elasticity, measured service, and so forth. A cloud-computing model may also come in the form of various service models such as, for example, Software as a Service ("SaaS"), Platform as a Service ("PaaS"), and Infrastructure as a Service ("laaS"). The cloud-computing model may also be deployed using different deployment models such as private cloud, community cloud, public cloud, hybrid cloud, and so forth.

Claim 1:
A computer system (<NUM>) for part production using flow infill design, comprising:
one or more processors (<NUM>); and
one or more computer-readable media (<NUM>) having stored thereon executable instructions that when executed by the one or more processors (<NUM>) configure the computer system (<NUM>) to perform at least the following:
receive a computer-aided design (CAD) file that describes physical dimensions of a target object (<NUM>);
identify a physical boundary portion (<NUM>) of the target object within the CAD file, wherein the physical boundary portion (<NUM>) comprises a portion of the target object that is configured to enclose a coreactive infill material (<NUM>);
generate a first tool path to additively manufacture the physical boundary portion (<NUM>);
send instructions to a dispenser (<NUM>, <NUM>) that cause the dispenser (<NUM>, <NUM>) to implement the first tool path while dispensing a boundary material; and
generate a command to dispense the coreactive infill material (<NUM>) within the physical boundary portion (<NUM>), wherein the coreactive infill material (<NUM>) chemically bonds with the boundary material.