Unsupported part with a robotic additive manufacturing system

Abstract

A method of printing a hollow part with a robotic additive manufacturing system includes extruding thermoplastic material onto a build platform movable in at least two degrees of freedom in a helical pattern along a continuous 3D tool path with an extruder mounted on a robotic arm, to thereby print a hollow member having a length and a diameter. The method includes orienting the hollow member during printing by moving the build platform based on a geometry of the hollow member wherein the movement of the build platform and the movement of the robotic arm are synchronized to print the part without support structures.

1 . (canceled) 
     
     
         2 . A method of printing a 3D part with a robotic additive manufacturing system, the method comprising:
 extruding thermoplastic material onto a build platform configured to tilt in x and y directions, the extruding performed in a prescribed pattern in a series of first tool paths with an extruder mounted on a robotic actuator configured to move the extruder in a plurality of degrees of freedom so as to print a first portion of a part in the series of first toolpaths, wherein the first portion has cooled to a temperature below a solidification temperature;   preheating an outer surface of the first portion of the along a second 3D tool path to heat a localized region on the outer surface to a temperature above a glass transition temperature of the material of the first portion;   conformally printing a second portion onto the outer surface of the first portion by extruding thermoplastic material onto the surface of the first portion along the second 3D tool path while the localized region on the first surface is above the glass transition temperature; and   orienting the second portion during said printing and conformal printing by moving the build platform based on a geometry of the first portion and the second portion, wherein the movement of the build platform and a movement of the robotic arm are synchronized to print the second portion and wherein the second portion and the localized region of the surface of the first portion bond while cooling to the solidification temperature.   
     
     
         3 . The method of  claim 2  and further comprising orienting the first portion of the part during said printing by moving the build platform in more than one degree of freedom based on a geometry of the first portion of the part, wherein the movement of the build platform and a movement, of the robotic arm are synchronized to print the first portion of the part the series of toolpaths; 
     
     
         4 . The method of  claim 2 , and further comprising incrementing the build platform along the z-axis as the material is extruded while the first portion or the second portion is printed. 
     
     
         5 . The method of  claim 2 , wherein one of the series of tool first paths comprises a helical 3D tool path such that the first portion comprises a hollow member. 
     
     
         6 . The method of  claim 2 , wherein the second portion of the 3D part is printed from a different thermoplastic material than is used to print the first portion of the 3D part. 
     
     
         7 . The method of  claim 2 , wherein the robotic actuator comprises a robotic arm. 
     
     
         8 . The method of  claim 7 , wherein the robotic arm is configured to move in six degrees of freedom. 
     
     
         9 . The method of  claim 2 , wherein the 3D part is a net or near-net part. 
     
     
         10 . A method of printing a 3D part with a robotic additive manufacturing system, the method comprising:
 printing a first portion of the 3D part by extruding thermoplastic material onto a build platform tiltable in x and y directions along a first tool path with an extruder mounted on a robotic actuator movable in a plurality of degrees of freedom, wherein the first portion has cooled to a solidification temperature of the extruded thermoplastic material;   after printing the first portion of the 3D part, preheating localized region of a surface of the first portion along a second tool path to a temperature above a glass transition temperature of the thermoplastic material;   conformally printing a second portion of the 3D part onto the first portion of the 3D by extruding thermoplastic material onto the localized region of the surface of the first portion of the 3D part along the second tool path wherein the second toolpath forms a contact edge of the second portion of the 3D part and the preheating aids in bonding the second portion to the first portion; and   orienting the first portion of the 3D part during printing by moving the build platform based on a geometry of the first portion of the 3D part and the second portion of the 3D part, wherein the movement of the build platform and the movement of the robotic arm are synchronized to print the 3D part without support structures and wherein the second portion and the localized region of the surface of the first portion bond while cooling to the solidification temperature.   
     
     
         11 . The method of  claim 10 , and further comprising incrementing the build platform along the z-axis as the material is extruded while the first portion or the second portion is printed. 
     
     
         12 . The method of  claim 10 , wherein the build platform is configured to rotated about a z-axis. 
     
     
         13 . The method of  claim 10 , wherein the robotic actuator comprises a robotic arm. 
     
     
         14 . The method of  claim 13 , wherein the robotic arm is configured to move in six degrees of freedom. 
     
     
         15 . A method of printing a 3D part with a robotic additive manufacturing system, the method comprising:
 printing a first portion of the 3D part by extruding thermoplastic material onto a build platform configured to tilt in the x and y directions along a first tool path with an extruder mounted on a robotic actuator configured to move in a plurality of degrees of freedom, wherein the temperature of the first portion actively or passively cools to a solidification temperature of the extruded thermoplastic material;   preheating a localized region of a surface of the first portion along a second tool path to a temperature above a glass transition temperature of the material of the first portion;   conformally printing a second portion of the 3D part onto the localized region of the surface of the first portion of the 3D by extruding thermoplastic material onto a surface of the first portion of the 3D part along the second tool path, wherein the second toolpath forms a contact edge of the second portion of the 3D part and the preheating aids in bonding the second portion to the first portion; and   orienting the first portion of the 3D part during printing by moving the build platform based on a geometry of the first portion of the 3D part and the second portion of the 3D part, wherein the movement of the build platform and the movement of the robotic arm are synchronized to print the 3D as a net or near-net part and wherein the second portion and the localized region of the surface of the first portion bond while cooling to the solidification temperature.   
     
     
         16 . The method of  claim 15 , and further comprising incrementing the build platform along the z-axis as the material is extruded while the first portion or the second portion is printed. 
     
     
         17 . The method of  claim 15 , wherein the build platform is configured to rotated about a z-axis. 
     
     
         18 . The method of  claim 15 , wherein the robotic actuator comprises a robotic arm. 
     
     
         19 . The method of  claim 18 , wherein the robotic arm is configured to move in six degrees of freedom. 
     
     
         20 . The method of  claim 15 , wherein the first portion of the 3D part comprises a hollow member having a length and a diameter that is printed along a helical 3D tool path. 
     
     
         21 . The method of  claim 15 , wherein the second portion of the 3D part is printed from a different thermoplastic material than is used to print the first portion of the 3D part.