Method of mediating print head cold end temperature during extrusion-based additive construction

Abstract

A carriageless print head assembly, for use in extrusion-based additive construction is disclosed. The carriageless print head features a cold end equipped with one or more timing belt attachment slots and bores for receiving bearings to achieve linear motion. The carriageless print head may be optionally equipped with some combination of an air conduit for cooling the top layer of the constructed product, a fluid channel for aiding in the regulation of the temperature of the print head cold end, and a thermal monitor for monitoring the temperature of the cold end of the print head. A computer-mediated method of monitoring the cold end of the print head to limit jams due to overheating is also disclosed.

What is claimed is: 
     
         1 . A method of performing extrusion-based additive construction using a 3D printer equipped with a print head and a controller, the print head comprising a hot end, a cold end, and a thermal monitor, the thermal monitor comprising a temperature sensor, the method comprising the steps of:
 a. beginning, by the 3D printer, an extrusion-based additive construction;   b. reading, by the temperature sensor, an operating temperature of the cold end;   c. assessing, by the controller, whether the operating temperature is above a predetermined temperature threshold;   d. pausing, by the controller, the construction for a predetermined amount of time and allowing the cold end to cool.   
     
     
         2 . The method of  claim 1 , further comprising the steps of
 e. reassessing, by the controller, whether the operating temperature is above the predetermined temperature threshold;   f. repeating steps d and e until the operating temperature is below the predetermined temperature threshold;   g. resuming, by the 3D printer, the extrusion-based additive construction.   
     
     
         3 . The method of  claim 1 , further comprising the step of:
 e. manually resuming, by a human operator, the extrusion-based additive construction.   
     
     
         4 . A method of performing extrusion-based additive construction using a 3D printer equipped with a carriageless print head and a controller, the carriageless print head comprising a hot end, a cold end, and a thermal monitor, the thermal monitor comprising a temperature sensor, the method comprising the steps of:
 a. beginning, by the 3d printer, an extrusion-based additive construction;   b. reading, by the temperature sensor, an operating temperature of the cold end;   c. assessing, by the controller, whether the operating temperature is above a predetermined temperature threshold;   d. pausing, by the controller, the construction for a predetermined amount of time and allowing the cold end to cool.   
     
     
         5 . The method of  claim 4 , wherein the cold end has a front end, a rear end, a left side, a right side, a top surface extending from the front end to the rear end and from the left side to the right side, and a bottom surface extending from the front end to the rear end and from the left side to the right side,
 wherein the left side has a first timing belt attachment slot adjacent to and aligned with a first receiver for receiving a first shaft, the first timing belt attachment slot extending substantially from the front end to the rear end, the first shaft extending substantially from the front end to the rear end,   wherein the right side has a second timing belt attachment slot adjacent to and aligned with a second for receiving a second shaft, the second timing belt attachment slot extending substantially from the front end to the rear end, the second shaft extending substantially from the front end to the rear end,   wherein the top surface is equipped with a first slot, a second slot, a third slot, and a fourth slot,
 the first slot extending downwardly towards the bottom surface and is configured to receive material feed, 
 the second slot extending downwardly towards the bottom surface and is configured to receive material feed, 
 the third slot extending downwardly towards the bottom surface and is configured to receive a cooling fluid, 
 the fourth slot extending downwardly towards the bottom surface and is configured to expel a cooling fluid, 
   wherein the carriageless print head is equipped with a first heat break, which is proximate to the first slot and a second heat break which is proximate to the second slot,   wherein the cold end is of a singular construction.   
     
     
         6 . The method of  claim 5 , wherein the thermal monitor is located within the cold end such that the temperature of the cold end may be monitored by the thermal monitor. 
     
     
         7 . The method of  claim 6 , the carraigeless print head further comprising:
 an air conduit extending downwardly from the top surface to the bottom surface, wherein the air conduit comprises a nipple extending upwardly from the top surface, and air duct extending downwardly from the nipple to the bottom surface, the air duct and the nipple being fluidly connected, wherein the air duct is equipped with a plurality of fins configured to optimize airflow from the nipple to the bottom surface;   a fluid channel having a perimeter,
 wherein the perimeter of the fluid channel is contained within the cold end and the perimeter is bounded by the bottom surface, the top surface, the front end, the rear end, the first receiver and the second receiver. 
   
     
     
         8 . The method of  claim 7 , further comprising the steps of
 h. reassessing, by the controller, whether the operating temperature is above the predetermined temperature threshold;   i. repeating steps d and e until the operating temperature is below the predetermined temperature threshold;   j. resuming, by the 3d printer, the extrusion-based additive construction.   
     
     
         9 . The method of  claim 7 , further comprising the step of:
 f. manually resuming, by a human operator, the extrusion-based additive construction.