Atmospheric plasma conduction pathway for the application of electromagnetic energy to 3d printed parts

Abstract

A three-dimensional (3D) printing process utilizing an atmospheric plasma to conduct an electromagnetic energy to fuse extruded successive layers of thermoplastic material having a conductive material is disclosed. A 3D printing system for the 3D printing process is also provided. The 3D printing system includes a 3D printer, an extrusion nozzle, a plasma emitter, and an electromagnetic energy source. The 3D printing process includes the steps of extruding a thermoplastic composite with the extrusion nozzle in successive layers to form a 3D part; directing a substantially evenly distributed plasma onto a predetermined location on the 3D part; and emitting an electromagnetic energy through the plasma. The plasma conducts the electromagnetic energy to the predetermined location on the 3D part. The thermoplastic composite includes a conductive material that generates heat by reacting to the electromagnetic energy.

1 . A three-dimensional (3D) printing process comprising the steps of:
 extruding through a filament extrusion channel defined in a nozzle body a thermoplastic composite in successive layers to form a 3D part, wherein the nozzle body has an extrusion end and the thermoplastic composite comprises a conductive material reactive to an electric current for heat generation;   exciting a gas to generate an atmospheric plasma with a first electrode comprising a first annular ring disposed around an annulus of the nozzle body adjacent to the extrusion end of the filament extrusion channel;   directing the atmospheric plasma onto a predetermined location on the 3D part; and   emitting the electric current into the plasma, wherein the plasma conducts the electric current to the predetermined location on the 3D part, and   wherein the conductive material interacts with the electric current conducted by the plasma to generate sufficient heat to fuse at least two adjacent successive layers at the predetermined location on the 3D part.   
     
     
         2 . The process of  claim 1 , further comprises an electromagnetic energy source configured to emit the electric current;
 wherein the plasma is substantially evenly distributed between the electromagnetic energy source and the 3D part.   
     
     
         3 . The process of  claim 2 , wherein the predetermined location on the 3D part is a location adjacent to where a newly extruded layer of the thermoplastic composite is deposited onto a previously extruded layer of the thermoplastic composite. 
     
     
         4 . The process of  claim 3 , wherein the electric current has sufficient power such that the conductive material generates sufficient heat to fuse the newly extruded layer of the thermoplastic composite with the previously extruded layer of the thermoplastic composite. 
     
     
         5 . The process of  claim 1 , wherein the conductive material comprises at least one nanomaterial selected from a group consisting of carbon nanotube, carbon black, buckyballs, graphene, and magnetic nanoparticles, and ferroelectric materials such as barium titanate. 
     
     
         6 . The process of  claim 1 , where the conductive material comprises a carbon nanotube selected from a group consisting of a single-wall carbon nanotubes (SWNT) and a multi-walled carbon nanotubes (MWNT). 
     
     
         7 . The process of  claim 1 , wherein the thermoplastic composite comprises at least one thermoplastic selected from a group consisting of acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), polyamide (PA), polyetheretherketone (PEEK), and high density polyethylene (HDPE). 
     
     
         8 . An extrusion nozzle for a three-dimensional (3D) printer having a ground reference, the extrusion nozzle comprising:
 a nozzle body defining a filament extrusion channel having an extrusion end; and   a plasma generating portion including a first electrode, wherein the first electrode is annular and disposed around an annulus of the nozzle body adjacent to the extrusion end of the filament extrusion channel,   wherein the plasma generating portion is configured to generate and discharge an atmospheric plasma capable of conducting an electric current between the first electrode and the 3D printer.   
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . The extrusion nozzle of  claim 8 , wherein the first electrode is configured to cooperate with a second electrode spaced from the first electrode to excite a gas there-between to form the atmospheric plasma. 
     
     
         15 . The extrusion nozzle of  claim 14 , wherein the second electrode is spaced from the extrusion nozzle. 
     
     
         16 . A three-dimensional (3D) printing system comprising:
 a 3D printer configured to print a 3D part by extruding successive layers of a thermoplastic composite comprising a conductive material that generates heat by reacting to an electric current, wherein the 3D printer comprises an extrusion nozzle including an extrusion end;   a plasma emitter configured to generate and directed a plasma toward the 3D part being printed, wherein the plasma emitter includes a first annular electrode located on the extrusion nozzle disposed about an annulus of the extrusion nozzle adjacent the extrusion end and a second electrode spaced from the extrusion nozzle; and   an electromagnetic energy source configured to generate and direct an electric current into the plasma such that the plasma conducts the electric current to the 3D part being printed.   
     
     
         17 . The three-dimensional (3D) printing system of  claim 16 , wherein electromagnetic energy source is adjacent to the extrusion nozzle. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . The three-dimensional (3D) print system of  claim 16 , further comprising:
 a first voltage source configured to power the plasma emitter; and   a second voltage source configured to power the electromagnetic energy source;   wherein the first voltage source is independent of the second voltage source.   
     
     
         21 . The extrusion nozzle of  claim 8 , wherein the nozzle body includes a heat break opposing the extrusion end. 
     
     
         22 . The extrusion nozzle of  claim 15 , wherein the second electrode is a conductive material on a printed 3D part. 
     
     
         23 . The extrusion nozzle of  claim 15 , wherein the second electrode is a coating on a surface of a thermoplastic filament. 
     
     
         24 . The three-dimensional (3D) printing system of  claim 16 , wherein the extrusion nozzle includes a heat break opposing the extrusion end. 
     
     
         25 . The three-dimensional (3D) printing system of  claim 16 , wherein the second electrode is a conductive material on a printed 3D part. 
     
     
         26 . The three-dimensional (3D) printing system of  claim 16 , wherein the second electrode is a coating on a surface of a thermoplastic filament.