Method for building three-dimensional models in extrusion-based digital manufacturing systems using ribbon filaments
AssigneeStratasys, Inc.
InventorsJ. Samuel Batchelder, William J. Swanson, S. Scott Crump
Life of this patent
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Abstract
A consumable material for use in an extrusion-based digital manufacturing system, the consumable material comprising a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric. The cross-sectional profile is configured to provide a response time with a non-cylindrical liquefier of the extrusion-based digital manufacturing system that is faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate.
Claims20
A method for building a three-dimensional model in an extrusion-based digital manufacturing system, the method comprising:
- feeding a ribbon filament of a consumable material to a ribbon liquefier retained by the extrusion-based digital manufacturing system, the ribbon filament having a length and a cross-sectional profile of at least a portion of the length that is axially asymmetric;
- melting the ribbon filament in the ribbon liquefier to provide a melted consumable material;
- extruding the melted consumable material from the ribbon liquefier;
- depositing the extruded consumable material in a layer-by-layer manner to form at least a portion of the three-dimensional model;
- changing a drive pressure for feeding of the ribbon filament to the ribbon liquefier, which exhibits a response time for extruding the melted consumable material that is at least 50% faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate;
- while extruding the melted consumable material, moving the ribbon liquefier at a rate that is based in part on the exhibited response time.
A method for building a three-dimensional model in an extrusion-based digital manufacturing system retaining an extrusion head, the method comprising:
- feeding a ribbon filament of a consumable material to a ribbon liquefier of the extrusion head, the ribbon filament having a length and a cross-sectional profile of at least a portion of the length, wherein the ribbon liquefier has an entrance cross-sectional area Ae and a hydraulic diameter Dh with the ribbon filament, and wherein Dh<0.95√{square root over (Ae)};
- melting the ribbon filament in the ribbon liquefier to provide a melted consumable material;
- extruding the melted consumable material from the ribbon liquefier;
- depositing the extruded consumable material in a layer-by-layer manner to form at least a portion of the three-dimensional model;
- changing a drive pressure for feeding of the ribbon filament to the ribbon liquefier, which exhibits a response time for extruding the melted consumable material that is at least 50% faster than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate;
- and
- while extruding the melted consumable material, moving the extrusion head at a rate that is based in part on the exhibited response time.
A method for building a three-dimensional model in an extrusion-based digital manufacturing system, the method comprising:
- providing a ribbon filament to the extrusion-based digital manufacturing system, the ribbon filament having a rectangular cross-sectional profile with a cross-sectional aspect ratio of width to thickness ranging from about 2.5:1 to about 20:1, wherein the ribbon filament comprises a thermoplastic material;
- feeding the ribbon filament to a ribbon liquefier retained by the extrusion-based digital manufacturing system, the ribbon liquefier having an entrance cross-sectional area Ae and a hydraulic diameter Dk with the ribbon filament, and wherein Dh<0.95√{square root over (Ae)};
- melting the ribbon filament in the ribbon liquefier to provide a melted consumable material that includes the thermoplastic material;
- extruding the melted consumable material from the ribbon liquefier;
- depositing the extruded consumable material in a layer-by-layer manner to form at least a portion of the three-dimensional model;
- changing a drive pressure for feeding of the ribbon filament to the ribbon liquefier, which exhibits a response time for extruding the melted consumable material that is at least 50% fast than a response time achievable with a cylindrical filament in a cylindrical liquefier for a same thermally limited, maximum volumetric flow rate;
- and
- while extruding the melted consumable material, moving the ribbon liquefier at a rate that is based in part on the exhibited response time.
Dependencies are inferred from the claim text.