THREE DIMENSIONAL PRINTING
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.
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)