Manufacturing in microgravity and varying external force environments

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising:
• feedstock;
• a filament 802;
• wherein the feedstock source being a feed stock cartridge removably attached to the additive manufacturing device, the feedstock cartridge containing and dispensing the filament 802 from a filament spool 706, the feedstock cartridge comprising:
• a casing having a filament dispensing opening;
• the filament spool 706 rotatably connected to an axle 2906, the axle 2906 connected to the casing, the filament spool 706 containing the filament 802;
• a filament guide tube 716 receiving the filament 802 within the casing and guiding the filament 802 through the filament dispensing opening to a location proximal to the material deposition component 104;
• at least one connection mechanism 2802 configured to removably attach the feedstock source 106 to the additive manufacturing device 100;
• and
• a filament guide tube monitor, the filament guide tube motor configured to cease feed motor operation when a filament break is detected within the filament guide tube 716;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material bonding component positioning system 102 configured to position the material bonding component 104 according to the part creation instructions;
• and
• a build volume, the part being created within the build volume according to the part creation instructions;
• wherein the filament 802 being fed into the material deposition component 104, the material bonding component 104 bonding each of the portions of the received feedstock according to part creation instructions via heating each of the portions of the received feedstock to a feedstock melting point and positioning the heated each of the portions of the feedstock

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material bonding component positioning system 102 configured to position the material bonding component 104 according to the part creation instructions;
• a build volume, the part being created within the build volume according to the part creation instructions;
• an enclosure 114, the enclosure 114 having an enclosed volume containing the material deposition component 104, the material positioning system 102, and the build volume, the enclosure 114 comprising an access door 128;
• and
• an environmental control unit 108 to regulate an enclosed volume environment to provide for the enclosure 114 to be airtight, the environmental control unit 108 further comprising a shutter assembly 6204 configured to regulate airflow through at least a portion of the environmental control unit 108;
• wherein the environmental control unit 108 is positioned within the enclosed volume and comprising at least one filter 6702 and at least one fan 6102.

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material bonding component positioning system 102 configured to position the material bonding component 104 according to the part creation instructions;
• a build volume, the part being created within the build volume according to the part creation instructions;
• and
• an enclosure 114, the enclosure 114 having an enclosed volume containing the material deposition component 104, the material positioning system 102, and the build volume, the enclosure 114 comprising an access door 128, a plurality of temperature sensors positioned throughout the enclosure 114, the plurality of temperature sensors being communicatively coupled to at least one control circuit, the at least one control circuit ceasing additive manufacturing device operation when a minimum number of the plurality of temperature sensors detects a temperature outside an operational range.

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a filament extruder 104, the filament extruder 104 to receive portions of the feedstock from the feedstock source 106, the filament extruder 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions, the filament extruder further comprising a release, operable by a hand for removably detaching the filament extruder from a material deposition positioning system 102;
• the material deposition positioning system 102 configured to position the material bonding component 104 according to the part creation instructions;
• and
• a build volume, the part being created within the build volume according to the part creation instructions;
• wherein the extruder 104 is replaceable and modular;
• and
• wherein the release further comprises:
• a push button dovetail release 3602;
• and
• a dovetail clip 3402 having a locking tongue 3404;
• and
• the material deposition positioning system 102 comprising an extruder bracket 3804 configured to removably receive the dovetail clip 3402 and attach the extruder 104.

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material deposition positioning system 102 to position the material bonding component 104 according to the part creation instructions, the material deposition positioning system comprising a plurality of linear actuators configured to manipulate one of:
• a build platform assembly 112 and a material deposition component 104, each of the linear actuators comprising:
• a linear actuator motor;
• a screw-driven linear rail operably connected to the motor;
• and
• a carriage connected for movement to the linear rail;
• wherein each of the linear actuators is connected to a common surface of the additive manufacturing device 100;
• and
• a build volume, the part being created within the build volume according to the part creation instructions;
• wherein the plurality of linear actuators comprising:
• a first vertically-oriented linear actuator 1102a connected to an additive manufacturing device backplate 130;
• a second vertically-oriented linear actuator 1102b connected to the additive manufacturing device backplate 130;
• a horizontally-oriented material deposition component linear actuator 1104 connected for vertical movement to a first vertically-oriented linear actuator carriage at a first end portion and to a second vertically-oriented linear actuator carriage at a second end portion, the material deposition component 104 connected for horizontal movement to a horizontally-oriented material deposition component linear actuator carriage, the a horizontally-oriented material deposition component linear actuator 1104 connected to the additive manufacturing device backplate 130;
• and
• a build platform assembly linear actuator 1106 connected to and extending tangentially from the additive manufacturing device backplate 130, a build platform assembly 112 connected for movement to a build platform linear actuator carriage 1116.

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material bonding component positioning system 102 configured to position the material bonding component 104 according to the part creation instructions, the material deposition positioning system 102 comprising a plurality of linear actuators configured to manipulate one of:
• a build platform assembly 112 and a material deposition component 104, each of the linear actuators comprising:
• a linear actuator motor;
• a screw-driven linear rail operably connected to the motor;
• and
• a carriage connected for movement to the linear rail;
• wherein each of the linear actuators is connected to a common surface of the additive manufacturing device 100;
• and
• a build volume, the part being created within the build volume according to the part creation instructions;
• wherein the plurality of linear actuators being:
• a horizontally-oriented linear actuator 1106 connected to an additive manufacturing device backplate 124;
• a horizontally-oriented material deposition component linear actuator 1102 connecting to a horizontally-oriented linear actuator carriage 5206 and extending tangentially from the horizontally-oriented linear actuator carriage 5206 for horizontal movement, the material deposition component 104 connected for horizontal movement to a horizontally-oriented material deposition component linear actuator carriage 5204;
• and
• a vertically-oriented build platform assembly linear actuator 1104 connected to the additive manufacturing device backplate 124, a build platform assembly 112 connected for movement to a build platform linear actuator carriage 5202.

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material bonding component positioning system 102 configured to position the material bonding component 104 according to the part creation instructions;
• a build volume, the part being created within the build volume according to the part creation instructions;
• a build platform assembly 112 positioned for movement within the build volume, the build platform assembly comprising:
• a build platform 5306;
• a plurality of alignment mechanisms 5404 contacting a build platform underside, configured to level the build platform 5306, the plurality of alignment mechanisms 5404 adjusting the orientation of the build platform 5306 during part creation;
• a build platform receiver 5302 connected at a first end portion to the material deposition positioning system 102, removably receiving the build platform 112 at a second end portion via a first build platform receiver channel 5310a and a second build platform receiver channel 5310b;
• wherein the plurality of alignment mechanisms 5404 are positioned within the build platform receiver 5302;
• and
• wherein each of the first build platform receiver channel 5310a and the second build platform receiver channel 5310b comprising a spring bar 5402 configured to contact and laterally stabilizes the build platform 5306.

An additive manufacturing device 100 operable in a microgravity environment to create a part, the additive manufacturing device comprising:

• a feedstock source 106 comprising feedstock;
• a material bonding component 104, the material bonding component 104 configured to receive portions of the feedstock from the feedstock source 106, the material bonding component 104 positioning and bonding each of the portions of the received feedstock according to part creation instructions;
• a material bonding component positioning system 102 configured to position the material bonding component 104 according to the part creation instructions;
• a build volume, the part being created within the build volume according to the part creation instructions;
• and
• control electronics 110 including a power supply and a thermal control circuit, the thermal control circuit and the power supply being electrically isolated.