System, method and apparatus for 3d printing

Abstract

The present invention is directed to three-dimensional printing techniques, methodologies, systems and apparatus to facilitate increased print speed. Through the use of multiple nozzles on a print head printing line by line, more material is deposited. By including nozzles sufficient for a line dimensional (or portion) of a page or planar element of an object design, the material deposition for an entire plane or layer is done line by line in one pass of the print head. Likewise, through the inclusion of multiple lasers, beams or energy sources more material can be cured, such as all along a contour line, instead of point by point.

1 . A three-dimensional printer comprising:
 a print head, said print head configured over an operational area;   a plurality of nozzles attached to and underside of said print head, a material extruded from said nozzles employed to form an object; and   a processor, said processor configured to control the position of said print head over said operational area during the formation of said object, and configured to control the respective nozzles and the flow of said material therethrough,   wherein at least two of said nozzles, each independently controlled by and at the command of said processor, extrude material together in the formation of said object,   wherein said at least two of said nozzles together extrude material over separate areas of said operational area,   wherein the number of said plurality of nozzles on said print head is within the range of about 10-0,000.   
     
     
         2 . The three-dimensional printer according to  claim 1 , wherein said plurality of nozzles have a diameter within the range selected from the group consisting of about 5-10 μm, about 15-25 μm, about 20-40 μm, about 40-60 μm, about 50-100 μm, and combinations thereof. 
     
     
         3 . The three-dimensional printer according to  claim 1 , wherein the number of said plurality of nozzles on said print head is within the range selected from the group consisting of about 100-10,000, about 50-5,000, about 30-3,000, about 20-2,000 and about 10-1,000. 
     
     
         4 . The three-dimensional printer according to  claim 1 , wherein said plurality of nozzles on said print head are arranged in a row. 
     
     
         5 . The three-dimensional printer according to  claim 4 , wherein said plurality of nozzles on said print head are arranged linearly in at least two rows. 
     
     
         6 . The three-dimensional printer according to  claim 1 , wherein said plurality of nozzles on said print head are arranged offset. 
     
     
         7 . The three-dimensional printer according to  claim 1 , wherein said material extruded from said nozzles is selected from the group consisting of acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), high density polyethylene (HDPE), PC/ABS, polyphenylsulfone (PPSU), high impact polystyrene (HIPS) and combinations thereof. 
     
     
         8 . The three-dimensional printer according to  claim 1 , wherein said operational area has substantially rectilinear dimensions, said print head having a length substantially equivalent to one of said dimensions, said plurality of nozzles configured on said print head across said one dimension, said print head moving across said operational area in one pass for one layer. 
     
     
         9 . The three-dimensional printer according to  claim 8 , wherein said print head length is less than said one of said substantially rectilinear dimensions, said print head moving across said operational area in multiple passes. 
     
     
         10 . The three-dimensional printer according to  claim 9 , wherein said print head length is an integer fraction of said one of said substantially rectilinear dimensions. 
     
     
         11 . The three-dimensional printer according to  claim 8 , wherein said print head has a length and width substantially equal to said substantially rectilinear dimensions for said operational area, said plurality of nozzles arranged in an array across said print head and, at the command of said processor, a plurality of said nozzles extruding material together in the formation of one layer of said object. 
     
     
         12 . The three-dimensional printer according to  claim 1 , wherein said print head is interchangeable with a second print head, said second print head having a different configuration of said plurality of nozzles. 
     
     
         13 . A print head for a three-dimensional printer comprising:
 a body; and   a plurality of nozzles attached to said body, a material extruded therefrom employed to form an object;   said print head configured, at the command of a processor, to position over an operational area and to extrude material from at least two of said nozzles together to form said object,   wherein said processor is configured to control the respective nozzles and the flow of said material therethrough,   wherein said at least two of said nozzles extrude material together over separate areas of said operational area, and   wherein the number of said plurality of nozzles on said body is within the range of about 10-10,000.   
     
     
         14 . The print head according to  claim 13 , wherein said nozzles have a diameter within the range selected from the group consisting of about 5-10 μm, about 15-25 μm, about 20-40 μm, about 40-60 μm, about 50-100 μm, and combinations thereof. 
     
     
         15 . The print head according to  claim 13 , wherein the number of said plurality of nozzles on said print head is within the range selected from the group consisting of about 100-10,000, about 50-5,000, about 30-3,000, about 20-2,000 and about 10-1,000. 
     
     
         16 . The print head according to  claim 13 , wherein said plurality of nozzles on said print head are arranged in a row. 
     
     
         17 . The print head according to  claim 16 , wherein said plurality of nozzles on said print head are arranged linearly in at least two rows. 
     
     
         18 . The print head according to  claim 13 , wherein said plurality of nozzles on said print head are arranged offset. 
     
     
         19 . The print head according to  claim 13 , wherein said print head, in operation, is positioned over an operational area, said operational area having substantially rectilinear dimensions, said print head having a length substantially equivalent to one of said dimensions, said plurality of nozzles configured across said print head across said one dimension, said print head moving across said operational area in one pass for one layer. 
     
     
         20 . The three-dimensional printer according to  claim 19 , wherein said print head length is less than said one of said substantially rectilinear dimensions. 
     
     
         21 . The three-dimensional printer according to  claim 20 , wherein said print head length is an integer fraction of said one of said substantially rectilinear dimensions. 
     
     
         22 . The three-dimensional printer according to  claim 19 , wherein said print head has a length and width substantially equal to said substantially rectilinear dimensions for said operational area, said plurality of nozzles arranged in an array across said print head, and, at the command of said processor, a plurality of said nozzles extruding material together in the formation of one layer of said object. 
     
     
         23 . A methodology for creating an object from a three-dimensional printer comprising:
 moving a print head over an operational area during the construction of an object, said print head having a plurality of nozzles attached thereto;   controlling, by a processor, said plurality of nozzles, said processor configured to control the position of said print head over said operational area during the formation of said object, and configured to control the respective nozzles and the respective flow of material extruded therethrough; and   extruding said material from at least two of said plurality of nozzles together during a pass of said print head over said operational area, said material extruded therefrom employed to form said object,   wherein at least two of said plurality of nozzles extrude material together over separate areas of said operational area,   wherein the number of said plurality of nozzles on said print head is within the range of about 10-10,000.   
     
     
         24 . A methodology for creating an object from a three-dimensional printer comprising:
 depositing a curable material for an object onto an operational area by at least one nozzle;   moving at least two energy beams, during a pass, over said operational area;   controlling, by a processor, said at least two energy beams, said processor configured to control the depositing of said curable material onto said operational area, and configured to control the position and intensity of said beams of energy over and onto said curable material on said operational area during the formation of said object; and   curing said curable material within said operational area, said curable material being cured, after said movement in said pass, in at least two separate positions within said operational area,   wherein said at least two energy beams are directed over separate areas of said operational area, and   wherein the number of said energy beams under processor control is within the range of about 10-10,000.