Systems and methods for forming three dimensional objects

Abstract

The present technology provides a three-dimensional (3D) printing system for forming 3D objects. The system includes a base plate, a first nozzle, a second nozzle, and a curing agent. The first nozzle can be configured to form a base layer of an object on the base plate and to form a contour of a second layer of the object on the base layer with a first material. The contour defines a volume within the second layer. The second nozzle can be configured to at least partially fill the volume within the second layer with a second material. The contour of the second layer and the second material form the second layer. The curing agent can be configured to solidify the second material.

1 . A system comprising:
 a base plate;   a first nozzle configured to form a base layer of an object on the base plate, and to form a contour of a second layer of the object on the base layer with a first material, wherein the contour defines a volume within the second layer;   a second nozzle configured to at least partially fill the volume within the second layer with a second material, wherein the contour of the second layer and the second material form the second layer; and   a curing agent configured to solidify the second material.   
     
     
         2 . The system of  claim 1 , wherein the first nozzle is configured to form a contour of a third layer of the object on at least a portion of the second layer with the first material, wherein the contour defines a volume within the third layer; and
 wherein the second nozzle is configured to at least partially fill the volume within the third layer with the second material, and wherein the contour of the third layer and the second material form the third layer.   
     
     
         3 . The system of  claim 1 , wherein the first nozzle is configured to:
 form a contour of a third layer of the object at least partially outside at least one of the contour of the first layer and the contour of the second layer; and   form a support layer between a third contour layer and at least one of the contour of the first layer and the contour of the second layer.   
     
     
         4 . The system of the  claim 1 , further comprising a dispensing pump coupled to the second nozzle via a conduit; wherein the dispensing pump is coupled to a reservoir, and wherein the reservoir is configured to hold the second material. 
     
     
         5 . The system of  claim 1 , further comprising:
 a vibrating element coupled to the base plate; and   a blade coupled to the second nozzle, wherein the blade is positioned above the second layer of the object, and wherein the blade is configured to level the second layer of the object.   
     
     
         6 . The system of  claim 1 , further comprising a processor configured to:
 control operation of the first nozzle, the second nozzle, and the curing agent;   calculate an amount of material to fill the volume within the second layer of the object; and   transmit a command to a dispensing pump, wherein the command comprises an instruction to fill the volume with the amount of material.   
     
     
         7 . The system of  claim 1 , wherein the first material comprises a thermoplastic polymer, wherein the second material comprises at least one of an ultraviolet (UV) curable polymer, a dual component material, and a heat curable material, and wherein a curing temperature of the second material is lower than a melting temperature of the first material. 
     
     
         8 . The system of  claim 5 , wherein the vibrating element is configured to vibrate the base plate at a frequency of about 1 Hz to about 100 Hz, at accelerations of about 0.01 g to about 0.1 g. 
     
     
         9 . A system comprising:
 a first nozzle configured to:
 form a base layer of an object on a base plate; and 
 form a contour of a second layer of the object on the base layer, wherein the contour defines a volume within the second layer; 
   a second nozzle configured to fill at least a portion of the volume within the second layer of the object with a material, wherein the contour and the material form the second layer; and   a curing agent configured to solidify the material in the second layer of the object,   wherein the first nozzle is configured to simultaneously form a contour of a third layer of the object on at least a portion of the second layer such that an amount of time required to solidify the material in the second layer is about the same as an amount of time required to form the contour of the third layer.   
     
     
         10 . The system of  claim 9 , wherein the contour of the third layer defines a volume within the third layer, wherein the second nozzle is further configured to fill, at least a portion of the volume within the third layer of the object with a material, wherein the contour and the material form the third layer,
 wherein the contour of the formed third and subsequent layers occurs at the same time as solidification of the material in the previous layers.   
     
     
         11 . The system of  claim 9 , further comprising a vibrating element configured to vibrate the base plate to evenly distribute the material across the volume defined by the contour of the second layer of the object. 
     
     
         12 . The system of  claim 9 , further comprising a blade configured to level the second layer of the object prior to creation of the contour of the third layer of the object. 
     
     
         13 . The system of  claim 9 , wherein solidification of the material in the second layer of the object comprises exposure of the material in the second layer of the object to radiation from a ultraviolet (UV) lamp, to heat or a combination thereof. 
     
     
         14 . The system of  claim 9 , wherein the curing agent is configured to be inactive after a predetermined time, and wherein at least a portion of the material in the second layer of the object is at least partially solidified at the predetermined time. 
     
     
         15 . The system of  claim 9 , wherein the curing agent is configured to provide radiation at an intensity that partially solidifies the material in the second layer of the object, wherein a surface of the material in the second layer of the object retains an adhesive characteristic for coupling the second layer of the object to the third layer of the object; and wherein the intensity of the curing agent is configured to completely solidify the material in the second layer of the object after one or more additional layers have been formed on top of the second layer. 
     
     
         16 . The system of  claim 9 , further comprising a processor configured to:
 control operation of at least one of the first nozzle, the second nozzle, and the curing agent;   to calculate an amount of material to fill the volume within the second layer of the object; and   to transmit a command to a dispensing pump, wherein the command comprises an instruction to fill the volume within the second layer of the object with the amount of material.   
     
     
         17 . A system comprising:
 a first nozzle coupled to a support structure, wherein the first nozzle is configured to form a base layer of an object and to form a contour of a second layer of the object with a first material, and wherein the contour defines a volume within the second layer;   a second nozzle coupled to the support structure, wherein the second nozzle configured to at least partially fill the volume within the second layer with a second material, and wherein the contour and the second material form the second layer;   a curing agent coupled to the support structure, wherein the curing agent is configured to solidify the second material;   wherein the first nozzle is configured to simultaneously form a contour of a third layer of the object on at least a portion of the second layer wherein an amount of time required to solidify the second material is about the same as an amount of time required to form the contour of the third layer; and   a base plate coupled to a bottom portion of the support structure, wherein the first nozzle moves independently of the second nozzle.   
     
     
         18 . The system of the  claim 17 , further comprising:
 a dispensing pump coupled to the second nozzle via a conduit; and   the dispensing pump coupled to a reservoir, and wherein the reservoir is configured to hold the second material.   
     
     
         19 . The system of  claim 17 , further comprising:
 a vibrating element coupled to the base plate; and   a blade coupled to the second nozzle, wherein the blade is positioned above the second layer of the object, and wherein the blade is configured to level the second layer of the object.