Technical Field

The invention relates to a three dimensional printing system and method that enables to increase the printing quality in three dimensional printers and to prevent and / or eliminate the errors that occur during printing.

In particular, the invention is related to a three dimensional printing system and a working method of this system that allows printing with different composite materials in three dimensional printers that are produced by the Fused Deposition Modeling method and provides the prevention and / or elimination of unwanted form defects and printing errors during printing.

State of the Art

Additive manufacturing systems known as three dimensional printers are used in the production of many models or parts in industrial or commercial areas such as aviation, automotive and defense industry. Models or parts designed on a software are obtained as three dimensional solid structures thanks to three dimensional printers and various production methods are used to perform this process. In three dimensional printers, printing materials made of thermoplastic polymer and thermoplastic polymer composite materials called filaments are used in the Fused Deposition Modeling (FDM) method, which is most commonly used for the production process. Although the filaments used in three dimensional printers are generally made of polymer, short fiber reinforced polymer composite materials and continuous fiber reinforced polymer composite materials, by adding different reinforcing materials to the polymer material (matrix) it is possible to increase the strength of the filaments and of the three dimensional object produced, and to improve their physical properties.

In the process of producing the three dimensional object with the FDM method, the thermoplastic filament is melted in the three dimensional printer head (extruder) with the help of heat and the molten printing material is flowed over a surface through an opening called nozzle. The three dimensional printing head moves on an axis extending perpendicular to the floor and / or on two separate axes running parallel to the floor, allowing the molten material to flow along a user - defined path and solidify the flowed material in its location. By adding new layers on and / or next to a building layer created in this way, the three dimensional object designed by the user is produced. However, it is not possible to produce a three dimensional object with jumping movements, creating a gap in between, especially in three dimensional printing processes performed with continuous fiber - reinforced polymer composite material. In addition, during the production with continuous fiber - reinforced polymer composite material, problems occur in the adhesion of the molten printing material that is positioned on top of each other and / or side by side, and this causes the three dimensional object to be distorted or the three dimensional object cannot be created as a result of the separation of the layers completely. In addition, in printing processes performed with continuous fiber reinforced polymer composite material, unwanted form defects such as wrinkles and curling occur on edges or between the layers during the return movements made by the three dimensional printing head to lay the molten printing material side by side and / or on top of each other.

The patent document numbered US20160107379A1 in the prior art, a printing head system and method is explained, which enables three dimensional printing with continuous fiber reinforced and thermoplastic composite material. The said system consists of the first printing head that enables the extrusion process of the polymer material, the second printing head that ensures the flow of the continuous fiber - reinforced polymer material, the feeding elements that ensure the transmission of the printing materials to the first and second printing heads, and heaters that are connected with the first and the second printing heads and melt the printing materials. The movement of the print head system is used with driving elements containing motors to move it along two separate axes, one axis extending perpendicular to the floor and the other axis running parallel to the floor. The polymer material transferred from the first printing head used in the system in question is used to fill the gaps formed during the printing process with the fiber - reinforced polymer material transferred from the second printing head. However, the transfer of the pure polymer material and the continuous fiber - reinforced polymer material from the separate heads prevents the homogeneous combination of the printing material and adversely affects the adhesion of the layers or fillers on the three dimensional object thus formed. This situation causes to decrease the strength of the produced object and / or to deteriorate its form. In the said document, there is no mention of a solution to prevent undesirable form defects such as wrinkles and curling that occur on the edge or between the layers formed during the return movements made by the three dimensional printing head to lay the molten printing material side by side and / or on top of each other in the printing processes carried out with continuous fiber reinforced polymer material. In addition, due to the need for two separate printing heads for the operation of the system, the system becomes a cumbersome structure, causing both the production time to be prolonged and the total production cost to increase. In another patent document numbered US20140061974A1 in the prior art, a three dimensional printer system and method is explained that enables plurality of different printing materials to be flowed at the same time and continuous composite printing. The said system includes a nozzle that enables the flow of the first printing material, the extrusion element that enables the transfer of the first printing material to the nozzle, the feeding element that enables the second printing material to be transferred to the extrusion element and the feeding cap that prevents the first printing material from leaking into the feeding element through the extrusion element. During the operation of the said system, composite printing material is obtained by combining plurality of printing materials such as fiber reinforcement or polymer matrix in separate channels and combined in the nozzle or extrusion element. However, this process decreases the penetration efficiency of fiber reinforcement and polymer matrix into each other and causes the physical strength of the three dimensional object produced with the composite printing material obtained with this process to decrease and / or to deteriorate its form. In the said document, there is no mention of a solution to improve the adhesion efficiency of the printing materials to each other or to prevent undesirable form defects such as wrinkles and curling that occur on the edge or between the layers formed during the return movements made by the three dimensional printing head to lay the molten printing material side by side and / or on top of each other in the printing processes carried out during production.

In conclusion, there is a need for the development of a three dimensional printing system and method that improves the adhesion efficiency of molten printing material with each other placed on top of each other or side by side during three dimensional printing made by using composite printing material containing continuous fiber reinforced polymer and prevents undesired form defects such as wrinkles and curling that occur on or between the layers from forming during the return movements of the three dimensional printing heads to lay the molten printing material side by side and / or on top of each other.

Aim of the Invention

The present invention relates to a three dimensional printing system and method that meets the above - mentioned requirements, eliminates possible disadvantages and provides some additional advantages.

The main aim of the three dimensional printing system and method of the invention is to provide a three dimensional printing system and method that ensures the improvement of the strength of the three dimensional object by improving the adhesion / bonding efficiency of the molten printing material which is positioned side by side on an axis extending perpendicular to the floor and / or on the plane that lies parallel to the floor during three dimensional printing with composite printing material containing continuous fiber reinforced polymer during three dimensional printing process and protection of the form of the produced object.

Another aim of the invention is to provide a three dimensional printing system and method that enables the elimination of undesired form defects such as wrinkles or curving on the layers, on their edges or between the layers from being formed during the return movements made by the system to lay the molten printing material side by side and / or on top of each other.

Another aim of the invention is to provide a compact three dimensional printing system and method that does not require an extra system or element for the use of printing materials in tape or filament form with different cross - sectional forms and / or cross - sectional areas for the production of three dimensional objects.

Another aim of the invention is to provide a three dimensional printing system and method that enables the fast and effective bonding of the molten printing material heated during the printing process and the solid printing material that was previously laid and cooled.

Another aim of the invention is to provide a three dimensional printing system and method that prevents the printing material from causing system congestion and interruption of the printing process.

Another aim of the invention is to provide an efficient three dimensional printing system and method that reduces the occurrence of errors during the printing process, preventing material loss, and decreasing the total cost and printing time.

The three dimensional printing system developed with the present invention in order to achieve the above - mentioned aims in the most general form, which is suitable for use with at least one movement mechanism that enables the movement of the three dimensional printing head, to produce three dimensional objects and to reduce the structural defects and form defects that occur during production, comprises at least one body that enables the elements of the system to be carried and connected to the movement mechanism. Furthermore, it also comprises at least one first transport element enabling the elements connected on it to be supported and assisting them to be rotated about the axis extending perpendicular to the floor and at least one transmission element, which is in the form of a tube comprising at least one opening, which helps the printing material to be driven forward linearly. The system further comprises at least one pushing element which pushes the printing material for being laid on the surface / layer on which the printing process is performed and / or enables the extrusion operation be carried out; at least one second support element for positioning and supporting the printing material on the body and at least one heating element that is suitable for laying the printing material at a first viscosity value transmitted from the transmission element which makes the heat transfer on the printing material layer at a second viscosity value lower than the first viscosity value. In addition, the system comprises at least one pressing element that enables a pressing force to be applied on the printing material at its first viscosity value so that it approaches the floor. Furthermore, it comprises at least one connecting element which enables the heating element and the pressing element to be connected on the support element and to be rotated together with the support element; at least one first driving element enabling rotation of the first transport element and positioning of the heating element and the pressing element; at least one correction element that enables the cutting of undesired form defects in order to eliminate the gaps or faults on the produced three dimensional object and / or layer.

The three dimensional printing method suitable for use with the three dimensional printing system with the present invention comprises the steps of connecting the system on the movement mechanism and moving the system on the first axis, second axis and / or third axis in accordance with the form of the three dimensional object to be produced; rotating the first transport element in accordance with the direction of movement of the system on the plane parallel to the floor such that the heating element is positioned in front of the first transport element and the pressing element behind the first transport element; transferring heat onto the printing material layer at second viscosity which is lower than the first viscosity value and melting the surface of the printing material at the second viscosity value close to the system; transferring the printing material into the transmission element; laying the printing material at the first viscosity value over printing material layer at the second viscosity value; applying a pressing force on the printing material at the first viscosity value which is laid on the printing material layer at the second viscosity value; cutting undesired form defects after the system performs inclined / angled movement and / or rotation during the printing process and removing the gaps and / or faults on the produced three dimensional object and / or layer.

The structural and characteristic features and all the advantages of the invention will be understood more clearly by means of the figures given below and the detailed explanation made by referring to these figures, and therefore the evaluation should be made by taking into consideration these figures and detailed explanations.

Drawings to Help Understand of the Invention

In order to understand the structure and advantages of the present invention in the best way, it should be evaluated together with the figures explained below. Figure 1 : is a perspective view of the three dimensional printing system of the invention.

Figure 2: is another perspective view of the three dimensional printing system of the invention.

Figure 3: is another front view of the three dimensional printing system of the invention.

Figure 4: is a cross sectional view of the first transport element in the three dimensional printing system of the invention.

Description of the Part References

1 . Body

2. First transport element

3. Transmission element

4. Pushing element

5. Second transport element

6. Heating element

7. Pressing element

8. Connection element

9. First driving element

10. Correction element

1 1 . Heat exchanger element

12. Cooling unit

13. Second driving element

14. Guiding element

15. Sensing element

Detailed Description of the Invention

In this detailed description, preferred embodiments of the three dimensional printing system of the present invention and the method are described for the sole purpose of providing a better understanding of the subject without imposing any limitation impact.

The three dimensional printing system, whose exemplary view is given in Figure 1 , developed with the present invention which is suitable for use with at least one movement mechanism that enables the support and movement of a three dimensional printing head first along a first axis extending perpendicular to the floor and I or a second axis running parallel to the floor and / or a third axis running parallel to the floor and perpendicular to the second axis, that produces a three dimensional object using the Fused Deposition Modeling method with printing material of different cross - sectional form and / or value, preferably in a continuous fiber - reinforced polymer - containing composite structure and thermoplastic property, that increases the strength of the produced three dimensional object by reducing form defects, comprises at least one body (1 ), which is suitable for the connection of the system elements on it and allows the elements of the system to be supported and connected to the movement mechanism of the system. In addition, it also comprises at least one first transport element (2), extending on an axis perpendicular to the floor and containing at least one channel suitable for the passage of a tubular part, extending on the axis perpendicular to the floor in relation to the surface of the body (1 ) close to the floor, providing the support of the elements connected on it, preferably in the form of a shaft or a hollow cylinder, helping them to rotate around the axis extending perpendicular to the floor; at least one transmission element (3), located in the channel and extending along the axis perpendicular to the floor, in the form of a tube containing at least one opening suitable for the advancement of the printing material, which helps the printing material to be laid linearly on the surface / layer on which the printing process is performed, which is changeable in form and / or value to let pass through the printing materials of different cross - sectional area. The system is also comprises at least one pushing element (4) connected to the body (1 ) and located on the body (1 ) close to the end of the first transport element (2) away from the ground, that ensures the printing material in filament or band structure of different cross - sectional form and / or value to be pushed and / or extruded to be laid on the surface / layer on which printing is performed; at least one second support element (5), preferably in the form of a shaft or a cylinder, which is connected to the body (1 ) and enables the printing material in filament or tape form to be positioned and supported on the body (1 ); at least one heating element (6), preferably a laser, connected to the first transport element (2) in conjunction with the first transport element (2), suitable for laying the printing material of a first viscosity value transmitted from the transmission element (3) for the three dimensional printing process, which is rotatable about the axis extending perpendicular to the floor, that enables heat transfer onto the printing material layer of a second viscosity value lower than the first viscosity value and to increase the bonding / adhesion efficiency of the printing material of the first viscosity value with the printing material layer of the second viscosity value. In addition, the system comprises a pressing element (7), preferably in the form of a cylinder, in connection with the first transport element (2), together with the first transport element (2), capable of rotating around the axis extending perpendicular to the floor, for the three dimensional printing process, that allows a printing force to be applied on the printing material of the first viscosity value so that it is closer to the floor after being laid on the printing material layer of the second viscosity value, the printing material of the first viscosity value being transmitted from the transmission element (3) for three dimensional printing and to increase the bonding / adhesion efficiency of the printing material of the first viscosity value and the printing material layer of the second viscosity value. In addition, it comprises at least one connection element (8) connected to the first transport element (2), the first heating element (6) and the pressing element (7), that enables fixing of the heating element (6) and the pressing element (7) on the first transport element (2) and enables the rotation of the heating element (6) together with them, preferably suitable for adjusting the position of the pressing element (7) on the axis extending perpendicular to the floor; at least one first driving element (9), connected to the body (1 ) and the first transport element (2) and enabling rotation of the first transport element (2) and positioning of the heating element (6) and the pressing element (7) so that the heating element is positioned in front of the first transport element (2) and pressing element is positioned behind the first transport element (2); and at least one correction element (10), connected to the body (1 ), that enables the cutting of undesired form defects after the system performs inclined / angled movement and I or rotation during the printing process in order to eliminate the gaps or faults on the produced three dimensional object and / or layer.

In an embodiment of the three dimensional printing system developed with the present invention, the system is connected to the movement mechanism by means of the body (1 ). By means of the movement mechanism, the system is moved on the first axis, the second axis and / or the third axis, in accordance with the form of the three dimensional object designed and to be produced by the user. During this movement, by means of the first drive element (9) and the connection element (8), the first transport element (2) is rotated in such a way that the heating element (6) is positioned in front of the first transport element (2) and the pressing element (7) is positioned behind the first transport element (2) in accordance with the movement direction of the system on the plane parallel to the floor (on the second and third axis). Then, by means of the heating element (6), heat transfer is made onto the printing material layer of a second viscosity value that is suitable for laying the printing material of the first viscosity value which is lower than the first viscosity value, and the printing material of the second viscosity value is partially melted. Meanwhile, by means of the pushing element (4), printing material of the filament or tape - like structure located on the second support element (5) is transferred to the transmission element (3). After the heat transfer / melting process carried out by the heating element, the printing material of the first viscosity value is laid on the printing material of the second viscosity value by means of the transmission element (3).

Then, by means of the pressing element (7), a pressing force is applied on the printing material of the first viscosity value, which is transmitted from the transmission element (3) and is laid on the printing material layer of the second viscosity value, so as to make it approach the floor. Thus, the bonding / adhesion efficiency of the printing material of the first viscosity value and the printing material layer of the second viscosity value is increased. During the three dimensional printing process, after the system performs an inclined / angled movement and / or rotation movement, the correction element (10) ensures that unwanted form defects are cut to eliminate the gaps or errors on the produced three - dimensional object and / or layer. In this way, both the form defects / errors are eliminated and the physical strength of the produced three dimensional object is increased.

The three dimensional printing method developed with the present invention and suitable for use with the three dimensional printing system comprises the steps of connecting the system to the movement mechanism by means of the body (1 ) and moving the system along the first axis, second axis and / or the third axis in accordance with the form of the three dimensional object designed and to be produced by the user; rotating the first transport element (2) by means of the first driving element (9) and the connection element (8) in accordance with the movement direction of system on the plane parallel to the floor (on the second and third axis) so that the heating element (6) is positioned in front of the first transport element (2) and the pressing element (7) is positioned behind the first transport element (2); transferring heat to the printing material layer of a second viscosity value lower than the first viscosity value by means of the heating element (6) and melting the surface of the printing material of the second viscosity value close to the system; transferring the printing material of filament or tape structure located on the second support element (5) into the transmission element (3) by means of the pushing element (4); laying the printing material of the first viscosity value on the printing material of second viscosity layer by means of the transmission element (3); applying a pressure force on the printing material of the first viscosity value that is laid on the printing material layer of the second viscosity value by means of the printing element (7), so as to make it come closer to the floor, and increasing the bonding / adhesion efficiency of the printing material of the first viscosity value and the printing material layer of the second viscosity value with each other; cutting unwanted deformations by means of the correction element (10) after the system performs inclined / angled movement and / or rotation movement during the printing process and removing the gaps and I or faults on the produced three dimensional object and I or layer.

In a preferred embodiment of the invention, the said three dimensional printing system comprises a heat exchanger element (11 ), which is connected with the said first transport element (2), comprising at least one spiral shaped channel formed on the said first transport element (2)that allows the cooling fluid to be heated and moved away from the floor, that allows the heat to be dissipated and prevents the heat of the printing material of the said first viscosity value in the said first transport element (2) from being transmitted to other elements of the system.

In another preferred embodiment of the invention, the said three dimensional printing system comprises at least one cooling unit (12) connected to the said body (1 ) and to the said heat exchange element (1 1 ), preferably comprising a reservoir that provides the storage of a cooling liquid and the pump that provides the transmission of the cooling liquid and that sends a cooling liquid into the said heat exchanger element (11 ) for cooling the first transport element (2) and receives back the coolant whose temperature increases in the said heat exchanger element (11 ).

In another preferred embodiment of the invention, the said three dimensional printing system comprises at least one second driving element (13), preferably having pneumatic and / or electromechanical and / or hydraulic structure, which is connected with the said pressing element (7) and enables the said pressing element (7) to be moved in two different directions on the axis perpendicular to the floor.

In another preferred embodiment of the invention, the said three dimensional printing system comprises at least one guiding element (14), preferably in the form of a shaft and / or a cylinder, which is connected with the said body (1 ) and located on the said second support element (5), that prevents the printing material from being worn or broken during the transmission of the printing material to the said pushing element (4).

In another preferred embodiment of the invention, the said three dimensional printing system comprises at least one sensing element (15), which is preferably a proximity sensor, which is connected with the said body (1 ) and enables the determination of the position of the system on the axis extending perpendicular to the floor.

By means of the three - dimensional printing system and method developed with the present invention, in the three - dimensional printing process carried out with a composite printing material containing continuous fiber reinforced polymer, it is ensured that the adhesion / bonding efficiency of the printing material of the first viscosity value and the printing material layer of the second viscosity value is increased, which are positioned on top of each other and / or side by side, and unwanted form defects such as wrinkles and curling are prevented that occur on or between the layers during inclined movements and / or return movements made by the system. In this way, an efficient, effective and fast three - dimensional printing system and method is obtained, which increases the strength of the three dimensional object produced and prevents material loss due to printing errors and prolonging of the production process.