Fused filament fabrication using multi-segment filament

A device for fabricating a continuous thermoplastic filament having a plurality of segments, which comprises:

• a plurality of filament supply components for supplying a respective plurality of thermoplastic filaments;
• a pair of spaces apart support rails;
• a filament cutting component for cutting the thermoplastic filaments into segments;
• a plurality of filament guide components for guiding the respective thermoplastic filaments into position to be cut by the filament cutting component;
• and
• a filament segment joining section positioned after the filament cutting component;
• wherein the plurality of filament guide components are movable so as to alternatively and sequentially permit the plurality of filaments to be cut by the filament cutting component;
• wherein the plurality of filament guide components comprises a first reciprocally movable plate and a first filament guide mounted on the first reciprocally movable plate;
• wherein the plurality of filament guide components comprises a second reciprocally movable plate and a second filament guide mounted on the second reciprocally movable plate;
• wherein the first reciprocally moveable plate and the second reciprocally moveable plate respectively move reciprocally from side to side along the pair of spaced apart support rails;
• wherein the first reciprocally moveable plate, the second reciprocally movable plate, and the filament segment joining section are each substantially positioned on the same horizontal plane;
• and
• wherein the filament cutting component comprises vertically reciprocating knife which vertically reciprocates to cut at least one of the first thermoplastic filament and the second thermoplastic filament against the first reciprocally moveable plate or the second reciprocally movable plate.

A device for fabricating a continuous thermoplastic filament having a plurality of segments, which comprises:

• a first filament supply component for supplying a first thermoplastic filament, the first filament supply component being a first rotatable spool;
• a first reciprocally moveable plate;
• a first filament guide mounted on the first reciprocally moveable plate;
• a second filament supply component for supplying a second thermoplastic filament, the second filament supply component being a second rotatable spool;
• a second reciprocally moveable plate;
• a second filament guide mounted on the second reciprocally moveable plate;
• a pair of spaced apart support rails;
• a filament cutting component for cutting each of the first and second filaments into segments, each of the segments having a forward end and trailing end spaced apart from the forward end;
• a filament segment joining section positioned after the filament cutting component, the filament joining section having:
• a chamber for guiding and aligning the forward end of one segment of the first and second filaments into contact with the trailing end of the other segment of the first and second filaments;
• and
• a heater element for heating and joining the trailing end to the forward end when in contact to form a continuous thermoplastic filament having a plurality of segments;
• wherein the chamber is generally cylindrical and extends horizontally through the filament segment joining section;
• wherein the first and second reciprocally movable plates are movable so as to alternatively and sequentially permit the first and second filaments to be cut by the filament cutting component;
• wherein the first and second filaments are alternatively and sequentially advanced in a first direction towards the filament segment joining section, and wherein the first reciprocally movable plate and the second reciprocally movable plate are reciprocally movable in a second direction which is substantially orthogonal to the first direction so that the first and second filaments can be alternatively and sequentially advanced in the first direction;
• wherein the first reciprocally moveable plate and the second reciprocally moveable plate respectively move reciprocally from side to side along the pair of spaced apart support rails;
• wherein the filament cutting component comprises vertically reciprocating knife which vertically reciprocates to cut at least one of the first thermoplastic filament and the second thermoplastic filament against the first reciprocally moveable plate or the second reciprocally movable plate.