Increased inter-layer bonding in 3d printing

Abstract

Inter-layer bonding in objects manufactured by 3D printing techniques is improved by one or more targeted heat sources (THSs) that preheat a targeted portion of existing object material before additional material is added to the object. 3D Printing is also improved, optimized or calibrated by pre- or post-heating a targeted area. THS elements may be fixed, mobile, or a combination thereof to apply heat to targeted areas. A THS may be integrated in or as an add-on to an existing 3D printer. A THS controller may use 3D printer information, such as a current direction or a future direction of printing, to select one or more THSs and to perform other targeted heat operations, such as setting energy levels, aiming, moving, etc. Properties, e.g., strength, of 3D printed objects with improved interlayer bonding may, for example, be several multiples better than the same object printed without improved interlayer bonding.

What is claimed is: 
     
         1 . A device for three-dimensional printing of an object, comprising:
 a print head configured to deposit additional print material adjacent to print material previously deposited to form the object; and   a targeted heat source configured to heat a portion of the previously deposited print material prior to the deposition of the additional print material.   
     
     
         2 . The device of  claim 1 , wherein the targeted heat source is coupled to the print head. 
     
     
         3 . The device of  claim 1 , wherein the targeted heat source is integrated with the print head. 
     
     
         4 . The device of  claim 1 , wherein the targeted heat source is further configured to heat the portion of the previously deposited print material to a temperature within a predetermined temperature range. 
     
     
         5 . The device of  claim 1 , further comprising a controller configured to control the operation of the targeted heat source. 
     
     
         6 . The device of  claim 5 , wherein the controller is further configured to aim the targeted heat source. 
     
     
         7 . The device of  claim 5 , wherein the controller is further configured to identify a location of the portion of the previously deposited print material. 
     
     
         8 . The device of  claim 1 , wherein the targeted heat source is an optical fiber coupled laser diode. 
     
     
         9 . The device of  claim 1 , further comprising a second targeted heat source configured to heat the portion of the previously deposited print material prior to the deposition of the additional print material. 
     
     
         10 . The device of  claim 1 , wherein the target heat source is further configured to heat a portion of the additional print material after deposition. 
     
     
         11 . The device of  claim 1 , wherein the print head uses Fused Filament Fabrication to deposit additional material. 
     
     
         12 . A system, comprising:
 a print head configured to deposit additional print material adjacent to print material previously deposited to form the object; and   a targeted heat source configured to heat a portion of the previously deposited print material prior to the deposition of the additional print material.   
     
     
         13 . The system of  claim 12 , wherein the targeted heat source is further configured to heat the portion of the previously deposited print material to be within a predetermined temperature range. 
     
     
         14 . The system of  claim 12 , comprising a plurality of targeted heat sources, wherein a targeted heat source controller is configured to select at least one of the plurality of the targeted heat sources to preheat the portion of the previously deposited material based on at least one of a current direction or a future direction of printing by the print head. 
     
     
         15 . The system of  claim 14 , wherein the targeted heat source controller is configured to select an energy level for the at least one heating element based on at least one of a velocity of the print head, an acceleration of the print head, a distance of the at least one heating element to the previously deposited printed material, a type of the previously deposited printed material, a temperature of the previously deposited printed material, a time the previously deposited printed material was printed, an elapsed time since the previously deposited printed material was printed, or a rate of deposition of the additional print material. 
     
     
         16 . The system of  claim 12 , further comprising a second targeted heat source configured to heat the portion of the previously deposited print material prior to the deposition of the additional print material. 
     
     
         17 . A method comprising:
 monitoring the state of the state of a printer, a targeted heat source, and a printed material; and   pre-heating a targeted portion of existing printed material before a print head prints additional printed material that bonds with or adheres to the preheated targeted portion of the existing printed material.   
     
     
         18 . The method of  claim 17 , further comprising:
 activating at least one of a plurality of targeted heat sources to pre-heat the targeted portion of the existing printed material based on at least one of a current direction and a future direction of printing by the print head.   
     
     
         19 . The method of  claim 17 , further comprising:
 determining an energy level for the at least one targeted heat source based on at least one of a velocity of the print head, an acceleration of the print head, a distance of the at least one heating element to the existing printed material, a type of the existing printed material, a temperature of the existing printed material, a time at which the existing printed material was printed, an elapsed time since the existing printed material was printed, or a rate of deposition of the additional printed material.   
     
     
         20 . The method of  claim 18 , further comprising:
 post-heating existing material based on the state of the printer, the targeted heat source, and the printed material.