Single extruder configuration that enables multi-color extrusions in three-dimensional object printers
An additive manufacturing system has a plurality of manifolds in an extruder. Each manifold is connected to at least one nozzle of the extruder to enable the at least one nozzle to extrude thermoplastic material through a corresponding aperture in a faceplate mounted to the extruder. A plurality of valves is configured between each manifold and each nozzle connected to the manifold to enable the nozzles connected to a manifold to extrude thermoplastic material from the manifold selectively. The faceplate is also configured for rotation about an axis perpendicular to the faceplate to enable different orientations of the nozzles in the apertures of the faceplate. The different manifolds of the extruder enable a plurality of thermoplastic materials having a different property to be extruded simultaneously so the materials can join to one another while the materials are at an elevated temperature.
1. An apparatus comprising:
an extruder having a plurality of manifolds and a plurality of nozzles, each manifold being configured to store thermoplastic material and each manifold being operatively connected to at least one nozzle in the plurality of nozzles through which thermoplastic material from the manifold can be emitted and no two of the manifolds are operatively connected to a same nozzle;
a faceplate having a plurality of apertures, each aperture in the faceplate being configured to receive thermoplastic material extruded from a nozzle in the plurality of nozzles in a one-to-one correspondence to enable the extruded thermoplastic material to pass through the aperture;
at least one valve being operatively connected between a nozzle in the plurality of nozzles and the manifold to which the nozzle is operatively connected in the extruder, the at least one valve being configured to open and close the nozzle selectively;
a plurality of extrusion material supplies, each extrusion material supply being configured to supply extrusion material having a property that is different than the property of extrusion material provided by the other extrusion material supplies in the plurality of extrusion material supplies;
at least one heater having a plurality of channels, each channel of the at least one heater being operatively connected to only one extrusion material filament supply in the plurality of extrusion material filament supplies in a one-to-one correspondence between the plurality of channels and the plurality of extrusion material supplies and each channel in the heater being operatively connected to only one manifold in the extruder in a one-to-one correspondence between the plurality of channels and the plurality of manifolds in the extruder to enable thermoplastic material produced by each channel to enter the manifold to which the channel is operatively connected; and
a plurality of mechanical movers, each mechanical mover being configured to move extrusion material from the extrusion material supply operatively connected to one of the channels in the heater, each mechanical mover also being configured for independent control of a rate at which the extrusion material is supplied to the channel in the heater that is operatively connected to the extrusion material supply; and
a controller configured to operate the at least one valve to extrude thermoplastic material from each nozzle selectively.
2. The apparatus of claim 1 wherein at least one manifold is operatively connected to at least two nozzles.
3. The apparatus of claim 1 , the extruder and the faceplate being configured to move relative to an object in more than one direction.
4. The apparatus of claim 3 wherein the faceplate and the plurality of nozzles are configured for rotation about an axis perpendicular to the faceplate.
5. The apparatus of claim 4 wherein at least one manifold is operatively connected to more than one nozzle and none of the nozzles operatively connected to the at least one manifold are operatively connected to any other manifold of the extruder.
6. The apparatus of claim 5 wherein the at least one valve comprises a plurality of valves, each valve being operatively connected between the at least one manifold and each nozzle operatively connected to the at least one manifold, each valve being configured to open and close the nozzle operatively connected to the at least one manifold selectively; and
a controller operatively connected to each valve that is operatively connected between the at least one manifold and each nozzle operatively connected to the at least one manifold, the controller being configured to operate each valve to extrude thermoplastic material from each nozzle operatively connected to the at least one manifold selectively.
7. The apparatus of claim 6 further comprising:
another valve operatively connected between another nozzle in the plurality of nozzles and another manifold in the plurality of manifolds other than the at least one manifold;
at least one actuator operatively connected to the extruder; and
the controller also being operatively connected to the other valve and the at least one actuator, the controller being further configured to:
operate the at least one actuator to move the extruder in a direction and to orient the apertures of the faceplate;
operate the valves operatively connected between the at least one manifold and nozzles operatively connected to the at least one manifold; and
operate the other valve operatively connected between the other manifold and the other nozzle operatively connected to the other manifold to enable at least one of the nozzles operatively connected to the at least one manifold and the other nozzle operatively connected to the other manifold to extrude thermoplastic material simultaneously.
8. The apparatus of claim 7 , the controller being further configured to operate the at least one actuator to orient the apertures of the faceplate to enable thermoplastic material extruded from the at least one nozzle operatively connected to the at least one manifold and thermoplastic material extruded from the other nozzle operatively connected to the other manifold to be adjacent to one another.
9. The apparatus of claim 7 , the controller being further configured to operate the at least one actuator to orient the apertures of the faceplate to enable thermoplastic material extruded from the at least one nozzle operatively connected to the at least one manifold to be placed on thermoplastic material extruded from the other nozzle operatively connected to the other manifold.
10. The apparatus of claim 1 wherein the at least one heater comprises
a plurality of heaters, each heater being operatively connected to only one extrusion material filament supply in the plurality of extrusion material filament supplies in a one-to-one correspondence between the plurality of channels and the plurality of extrusion material supplies and each heater being operatively connected to only one manifold in the extruder in a one-to-one correspondence between the plurality of heaters and the plurality of manifolds in the extruder to enable thermoplastic material produced by each channel to enter the manifold to which the channel is operatively connected.