Three-dimensional printer systems and methods

Abstract

Disclosed are embodiments of a three-dimensional (3D) printer for building 3D objects with layer based, additive manufacturing techniques. The hot end can be moved in a horizontal plane parallel a planar printing surface of the printing bed while the printing bed can be moved perpendicular to the planar printing surface to print a 3D object. The hot end can be part of an extrusion guide assembly. The 3D printer can auto-level the printing bed.

What is claimed is: 
     
         1 . An extrusion assembly movement system for a three-dimensional printer, the system comprising:
 a frame comprising a first side and a second side opposite the first side;   a first rod connected to the frame, the first rod extending along an x-axis proximate to the first side of the frame;   a second rod connected to the frame, the second rod extending along the x-axis parallel to the first rod and proximate to the second side of the frame;   a first brace movably coupled to the first rod, the first brace capable of being translated on the first rod along the x-axis;   a second brace movably coupled to the second rod, the second brace capable of being translated on the second rod along the x-axis;   a third rod connected to the first and second braces, the third rod extending along a y-axis;   a fourth rod connected to the first and second braces, the fourth rod extending along the y-axis parallel to the third rod;   an extrusion assembly movably coupled to the third and fourth rods, the extrusion assembly capable of being translated on the third and fourth rods along the y-axis, the extrusion assembly configured to extrude consumable material to build a three-dimensional object;   a first plurality of rotating shafts positioned in a first plane along the x-axis and the y-axis, each of the first plurality of rotating shafts configured to rotate about a corresponding central axis;   a first belt fixedly coupled to the extrusion assembly, the first belt looped about the first plurality of rotating shafts in the first plane;   a first motor connected to the first belt, the first motor configured to move the first belt in the first plane about the first plurality of rotating shafts;   a second plurality of rotating shafts positioned in a second plane along the x-axis and the y-axis, each of the second plurality of rotating shafts configured to rotate about a corresponding central axis, the second plane parallel to the first plane;   a second belt fixedly coupled to the extrusion assembly, the second belt looped about the second plurality of rotating shafts in the second plane; and   a second motor coupled to the second belt, the first motor configured to move the second belt in the second plane about the second plurality of rotating shafts,   wherein the first and second motors spin in a same direction to move the extrusion assembly along the third and fourth rods in the y-axis via moving the first and second belts, and   wherein the first and second motors spin in opposite directions to move the extrusion assembly in the x-axis via moving the first and second brace along the first and second rods.   
     
     
         2 . The system of  claim 1 , the system further comprising:
 a first corner on the first side;   a second corner on the first side, the second corner opposite the first corner along the first side;   a third corner on the second side, the third corner opposite the second corner along a third side of the frame extending along the x-axis; and   a fourth corner on the second side, the fourth corner opposite the third corner along the second side;   a first rotating shaft of the first plurality of rotating shafts connected to the first brace in the first plane;   a second rotating shaft of the first plurality of rotating shafts connected to the second brace in the first plane;   a third rotating shaft of the first plurality of rotating shafts positioned proximate to the third corner in the first plane; and   a fourth rotating shaft of the first plurality of rotating shafts positioned proximate to the second corner in the first plane,   wherein the first motor is positioned proximate to the first corner, and   wherein the first belt extends from the first motor to the first rotating shaft, from the first rotating shaft to the second rotating shaft, from the second rotating shaft to the third rotating shaft, from the third rotating shaft to the fourth rotating shaft, and from the fourth rotating shaft to the first motor.   
     
     
         3 . The system of  claim 2 , the system further comprising:
 a fifth rotating shaft of the second plurality of rotating shafts connected to the second brace in the second plane;   a sixth rotating shaft of the second plurality of rotating shafts connected to the first brace in the second plane;   a seventh rotating shaft of the second plurality of rotating shafts positioned proximate to the second corner in the second plane; and   an eighth rotating shaft of the second plurality of rotating shafts positioned proximate to the third corner in the second plane,   wherein the second motor is positioned proximate to the fourth corner, and   wherein the second belt extends from the second motor to the fifth rotating shaft, from the fifth rotating shaft to the sixth rotating shaft, from the sixth rotating shaft to the seventh rotating shaft, from the seventh rotating shaft to the eighth rotating shaft, and from the eighth rotating shaft to the second motor.   
     
     
         4 . The system of  claim 3 , wherein a section of the first belt between the third rotating shaft and the fourth rotating shaft and a section of the second belt between the seventh rotating shaft and the eighth rotating shaft intersect when projected onto the first plane or the second plane. 
     
     
         5 . The system of  claim 1 , wherein the first and second rods are perpendicular to the third and fourth rods. 
     
     
         6 . The system of  claim 1 , wherein the first and second belts are passed through a body of the extrusion assembly to fixedly couple the first and second belts to the extrusion assembly, and wherein the first and second belts intersect when projected onto the first plane or the second plane. 
     
     
         7 . The system of  claim 1 , wherein the first and second belts are continuous. 
     
     
         8 . The system of  claim 1 , wherein the frame supports the system as a single unit and is configured to be installed and removed from a three-dimensional printer. 
     
     
         9 . A method of moving a hot end of a three-dimensional printer, the system comprising:
 moving a first belt positioned in a first plane via a first motor, the first belt looped about a first plurality of rotating shafts positioned in the first plane;   moving a second belt positioned in a second plane via a second motor, the second belt looped about a second plurality of rotating shafts positioned in the second plane, the second plane parallel to the first plane;   moving a first brace along a first rod extending along an x-axis via movement of at least one of the first belt or the second belt;   moving a second brace along a second rod extending along the x-axis via movement of at least one of the first belt or the second belt; and   moving a hot end of a three-dimensional printer along the x-axis, a y-axis, or both the x-axis and the y-axis via the hot end being movably connected to a third rod that is connected to the first and second braces along the y-axis, the hot end configured to extrude consumable material to build a three-dimensional object,   wherein the hot end is moved in the x-axis by the third rod being moved in the x-axis when the first and second braces are moved along the first and second rods via the first and second belts, and   wherein the hot end is moved in the y-axis by being moved on the third rod with via the first and second belts.   
     
     
         10 . The method of  claim 9 , wherein the first and second motors spin in a same direction to move the hot end in the y-axis along the third rod via moving the first and second belts, and wherein the first and second motors spin in opposite directions to move the hot end in the x-axis via moving the first and second brace along the first and second rods. 
     
     
         11 . The method of  claim 9 , comprising moving the hot end along the x-axis, a y-axis, or both the x-axis and the y-axis via the hot end being movably connected to the third rod and a fourth rod parallel to the third rod, the fourth rod connected to the first and second braces along the y-axis. 
     
     
         12 . The method of  claim 9 , wherein the step of moving the first belt in the first plane about the first plurality of rotating shafts via the first motor comprises:
 moving the first belt between the first motor and a first rotating shaft of the first plurality of rotating shafts, the first motor positioned proximate to a first corner of the three-dimensional printer, the first rotating shaft positioned proximate to a second corner of the three-dimensional printer, the second corner opposite the first corner along the x-axis;   moving the first belt between the first rotating shaft and a second rotating shaft of the first plurality of rotating shafts, the second rotating shaft positioned proximate to a third corner of the three-dimensional printer, the third corner opposite the second corner along the y-axis;   moving the first belt between the second rotating shaft and a third rotating shaft of the first plurality of rotating shafts, the third rotating shaft connected to the second brace;   moving the first belt between the third rotating shaft and a fourth rotating shaft of the first plurality of rotating shafts, the fourth rotating shaft connected to the first brace; and   moving the first belt between fourth rotating shaft and the first motor.   
     
     
         13 . The method of  claim 9 , wherein the step of moving the second belt in the second plane about the second plurality of rotating shafts via the second motor comprises:
 moving the second belt between the second motor and a fifth rotating shaft of the first plurality of rotating shafts, the second motor positioned proximate to a fourth corner of the three-dimensional printer, the fourth corner opposite the third corner along the x-axis, the fifth rotating shaft positioned proximate to the third corner;   moving the second belt between the fifth rotating shaft and a sixth rotating shaft of the second plurality of rotating shafts, the sixth rotating shaft positioned proximate to the second corner;   moving the second belt between the sixth rotating shaft and a seventh rotating shaft of the second plurality of rotating shafts, the seventh rotating shaft connected to the first brace;   moving the second belt between the seventh rotating shaft and an eighth rotating shaft of the second plurality of rotating shafts, the eighth brace connected to the second brace; and   moving the second belt between eighth rotating shaft and the second motor.