Pellet-Based Fused Deposition Modeling 3-D Print Process for Production Manufacturing

A method of manufacturing an object according to a fused deposition process, the method comprising:

• using a screw conveyor to convey a plurality of solid thermoplastic pellets from a hopper to a barrel;
• using a heating element, coupled to the barrel, to melt the solid thermoplastic pellets within the barrel, thereby producing a thermoplastic liquid;
• and
• extruding the thermoplastic liquid onto a build surface, through a nozzle that caps one end of the barrel, the extruded thermoplastic liquid thereafter solidifying into the object,
• wherein a control system controls both a flow rate of the thermoplastic liquid, by adjusting rotation of a motor coupled to the screw conveyor, and a position of the nozzle above the build surface according to a three-dimensional shape of the object.

A non-transitory, tangible, computer-readable storage medium comprising computer program code that, when executed by a computer, causes the computer to operate an extruder, thereby causing performance of a method comprising:

• using a screw conveyor to convey a plurality of solid thermoplastic pellets from a hopper to a barrel;
• using a heating element, coupled to the barrel, to melt the solid thermoplastic pellets within the barrel, thereby producing a thermoplastic liquid;
• and
• extruding the thermoplastic liquid onto a build surface, through a nozzle that caps one end of the barrel, the extruded thermoplastic liquid thereafter solidifying into the object,
• wherein the computer controls both a flow rate of the thermoplastic liquid, by adjusting a rotational speed of a motor coupled to the screw conveyor, and a position of the nozzle above the build surface according to a three-dimensional shape of the object.