Penetrating and actuating nozzle for extrusion-based 3d printing

Abstract

An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.

What is claimed is: 
     
         1 . A device for forming a strengthening feature in a void extending through a plurality of layers of a three-dimensionally printed composite, the device comprising:
 a movable arm having an end; and   a penetrating extension at the end, wherein the penetrating extension is sized and shaped to fit within the void.   
     
     
         2 . The device of  claim 1 , wherein the void has a depth and a first diameter perpendicular to the depth; and
 the penetrating extension has a second smaller diameter of the same shape relative to the first diameter.   
     
     
         3 . The device of  claim 1 , wherein the penetrating extension comprises a length of at least 50% of a depth of the void. 
     
     
         4 . The device of  claim 1 , wherein the penetrating extension is configured to rotate within the void. 
     
     
         5 . The device of  claim 1 , further comprising an extraction platen extending at least partially around, and movable with respect to, the penetrating extension. 
     
     
         6 . The device of  claim 1 , wherein the penetrating extension comprises a heated rod. 
     
     
         7 . The device of  claim 6 , wherein at least a portion of the rod is coated, the coating further comprising a heat-resistant, non-stick material. 
     
     
         8 . The device of  claim 1 , further comprising a nozzle including the penetrating extension, the penetrating extension including an internal passage. 
     
     
         9 . The device of  claim 8 , wherein the nozzle further comprises more than one penetrating extension configured to insert into more than one void. 
     
     
         10 . The device of  claim 8 , the nozzle further comprising a longitudinal side wall and a bottom end, wherein the side wall comprises at least one extrusion hole at the bottom end, wherein the at least one extrusion hole connects with the internal passage. 
     
     
         11 . A device for forming a strengthening feature in a void extending through a plurality of layers of a three-dimensionally printed composite, the device comprising:
 a nozzle adapted to receive and deposit a polymer material, and including a penetrating extension sized and shaped to insert into the void of the printed composite to deposit the polymer material into the void.   
     
     
         12 . The device of  claim 11 , the nozzle further comprising a longitudinal side wall and a bottom end, wherein the side wall comprises at least one exit channel at the bottom end. 
     
     
         13 . The device of  claim 11 , wherein the penetrating extension comprises a polymer passageway extending therethrough to the at least one exit channel. 
     
     
         14 . The device of  claim 11 , wherein the penetrating extension further comprises one of a plurality of polygonal shapes, wherein one of the plurality of polygonal shapes is a rectangular shape. 
     
     
         15 . The device of  claim 14 , wherein the rectangular shape penetrating extension is configured to rotate within the void to contact at least one wall of the void. 
     
     
         16 . The device of  claim 15 , the void comprising a plurality of depths of increasing and decreases diameters across the depth of the void. 
     
     
         17 . A method for additive manufacturing comprising the steps of:
 depositing at least one layer of a material in a two-dimensional plane and defining a void having a depth oriented perpendicular to the two-dimensional plane;   inserting a nozzle into the void;   receiving and depositing a polymer material into the void at an interval of the at least one layer of material using the nozzle.   
     
     
         18 . The method of  claim 17 , further comprising depositing layers to make a void area, wherein the void area has a plurality of increasing and decreasing diameters across the depth of the void area, wherein the void area is configured to a polygonal shape. 
     
     
         19 . The method of  claim 17 , wherein the nozzle is configured to the same polygonal shape as the void area, wherein the nozzle further comprises rotating adapted to contact at least one wall of the void area. 
     
     
         20 . The method of  claim 18 , wherein the void areas each extend through more than one layer of material, the void areas being in a staggered pattern across the two-dimensional plane.