System and method for 3D printing parts with additional features
An apparatus and method for multi-stage printing teaches a 3D printer in combination with one or more additional dispensing nozzles. One or more additional dispensing nozzles are combined with the 3D for filling cavities with other compounds such as foam, sterilizing parts by spraying printed mold with disinfectant or antibacterial treatments, and embedding parts or other materials such as paper, fiberglass, or carbon fiber within the printing layers for additional strength and changing mold properties of a final product. In other embodiments, the apparatus of the present invention can be used in combination with a robotic packaging mechanism for bagging sterilized parts for shipment.
1. A method for multi-stage 3D printing combined with insulation, sterilization, and embedding, consisting of
a 3D printer;
one or more additional nozzles for emitting chemicals for insulation, sterilization, and embedding onto, in, or around a printed part while the printed part is still in a printing chamber; and
printing the part in an upside down orientation when printing with a foam material that is less dense when compared to the atmosphere of the printing environment.
2. The method of claim 1 , wherein the nozzles emit a foam compound to fill cavities in the printed part as it is being printed.
3. The method of claim 1 , wherein the nozzles emit a dye coloring into a plastic or a foam as it is being printed or filled.
4. The method of claim 1 , wherein the nozzles emit a disinfectant or antibacterial compound to sterilize printed parts.
5. The method of claim 4 , in combination with an automatic packaging system for bagging printed and sterilized parts for shipping.
6. The method of claim 1 , further comprising the steps of embedding the printed device with fiberglass, carbon fiber, or other filaments; and
the nozzles emitting a chemical compound acting as a surface coating for the fiberglass, or carbon fiber.
7. The method of claim 1 , wherein the nozzles provide additional heating for plastic droplets added during printing of a part so that the plastic droplets can be absorbed or soaked into one or more prior or subsequently printed embedded materials during the printing of the part.
8. The method of claim 1 , wherein the chamber is maintained as sterile.
9. The method of claim 1 , wherein the nozzles emit structural foam.
10. The method of claim 1 , wherein the nozzles emit a water barrier closed cell foam.
11. The method of claim 1 , wherein the nozzles emit a removable support.
12. The method of claim 1 , wherein a vacuum is maintained in the chamber.
13. The method of claim 12 , wherein
the vacuum in the chamber creates vacuumed chambers in the part
a gaseous mixture is pumped into the chamber to replace the atmosphere; and
the chambers are filled in a part with inert gases or lighter gases to change buoyancy properties of the printed part.
14. The method of claim 1 , wherein a gaseous atmosphere is maintained in the chamber.
15. The method of claim 14 , wherein the gaseous atmosphere is comprised of inert gases.
16. The method of claim 15 , wherein the gaseous atmosphere in the chamber creates gaseous pockets trapped in the part.