Three dimensional printing

Abstract

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

What is claimed is: 
     
         1 . A method for manufacturing a part, the method comprising:
 feeding a void free core reinforced filament into an extrusion nozzle, wherein the core reinforced filament comprises a core and a matrix material surrounding the core;   heating the core reinforced filament to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core; and   extruding the core reinforced filament to form the part.   
     
     
         2 . The method of  claim 1  wherein the matrix material comprises a thermoplastic resin. 
     
     
         3 . The method of  claim 1 , wherein extruding the core reinforced filament further comprises extruding the core reinforced filament under compression. 
     
     
         4 . The method of  claim 1 , wherein extruding the core reinforced filament further comprises extruding the core reinforced filament over an unsupported area. 
     
     
         5 . The method of  claim 4 , further comprising forming a solid shell with the core reinforced filament. 
     
     
         6 . The method of  claim 1 , further comprising extruding the core reinforced filament in a first direction in a first portion of a part and in a second direction in a second portion of the part. 
     
     
         7 . The method of  claim 1 , further comprising cutting the core reinforced filament at or upstream from an outlet of the nozzle. 
     
     
         8 . The method of  claim 7 , further comprising cutting the core reinforced filament between the outlet of the nozzle and a feeding mechanism. 
     
     
         9 . The method of  claim 1 , wherein the core comprises at least one of an electrically conductive, optically conductive, and fluidly conductive component. 
     
     
         10 . The method of  claim 9 , further comprising forming a part with at least one of an integrated electrical component, optical component, or fluidic component. 
     
     
         11 . The method of  claim 1 , wherein the core is a multifilament core. 
     
     
         12 . The method of  claim 1 , wherein the core is a solid core. 
     
     
         13 . The method of  claim 1 , wherein extruding the core reinforced filament further comprises extruding the core reinforced filament through a rounded outlet of the extrusion nozzle. 
     
     
         14 . The method of  claim 1 , wherein the core is a continuous core. 
     
     
         15 . The method of  claim 1 , wherein the core is a semi-continuous core. 
     
     
         16 . The method of  claim 1 , further comprising pulling the filament out of the nozzle when a dragging force applied to the filament is greater than a force threshold of an associated feeding mechanism. 
     
     
         17 - 93 . (canceled) 
     
     
         94 . A method for manufacturing a part, the method comprising:
 feeding a filament into a heated extrusion nozzle;   extruding the filament from a nozzle outlet; and   applying a compressive force to the extruded filament with the nozzle.   
     
     
         95 . The method of  claim 94 , further comprising heating the extruded filament with the nozzle as the nozzle applies a compressive force. 
     
     
         96 . The method of  claim 94 , wherein feeding the filament into the heated extrusion nozzle further comprises feeding a core reinforced filament into the heated extrusion nozzle. 
     
     
         97 . The method of  claim 96 , wherein the reinforced filament is substantially solid when fed into the extrusion nozzle. 
     
     
         98 . The method of  claim 94 , wherein a rounded lip of the nozzle applies a compressive force to the extruded filament. 
     
     
         99 - 104 . (canceled)