Additive manufacturing system with extended printing volume, and methods of use thereof
An additive manufacturing system for printing three-dimensional parts, the system comprising a heatable region, a receiving surface, a print head configured to print a three-dimensional part onto the receiving surface in a layer-by-layer manner along a printing axis, and a drive mechanism configured to index the receiving surface along the printing axis such that the receiving surface and at least a portion of the three-dimensional part out of the heated region.
1. An additive manufacturing system for printing a three-dimensional part, the system comprising:
a build environment having a first length;
a gantry located within the build environment;
a print head attached to the gantry, wherein the gantry is configured to move the print head in a plane substantially parallel to a print plane, wherein a part material is extruded in the print plane to print the three-dimensional part in a layer-by-layer manner, wherein the print plane is non-horizontal;
a receiving surface configured to receive the printed part material from the print head to build the three-dimensional part in the layer-by-layer manner to a selected part length where the part length is greater than the first length of the build environment; and
a drive mechanism configured to index at least a portion of the receiving surface substantially parallel to a printing axis such that the receiving surface and at least a portion of the three-dimensional part move out of the build environment as the three-dimensional part is being built in the layer-by layer manner.
2. The system of claim 1 , wherein the build environment is unheated.
3. The system of claim 1 , wherein the build environment comprises one or more heaters configured to heat the build environment proximate the build plane.
4. The system of claim 1 , wherein the build environment comprises a chamber having chamber walls and a port, and wherein the indexing moves the receiving surface and at least a portion of the three-dimensional part through the port.
5. The system of claim 1 , wherein the build environment comprises a plurality of chambers in series, and wherein the indexing moves the receiving surface and at least a portion of the three-dimensional part through each of the plurality of chambers, wherein each of the plurality of chambers is configured to be heated to different temperatures to define a step-down temperature gradient.
6. The system of claim 1 , wherein the printing axis comprises a substantially non-vertical printing axis.
7. The system of claim 1 , wherein the drive mechanism comprises a rotatable belt configured to accept and support the extruded material as the three-dimensional part is printed in the layer-by-layer manner.
8. The system of claim 7 , and further comprising one or more post-printing processing stations, wherein the rotatable belt extends through the one or more post-printing processing stations.
9. A method of print a three-dimensional part in a layer by layer manner, the method comprising:
providing a build environment having a first length;
providing a gantry located within the build environment and carrying a print head configured to extrude molten material in a series of roads to form each layer of the three-dimensional part;
heating the material to a molten state;
extruding the molten material in the series of roads to form one or more layers of the three-dimensional part by causing the gantry to move the print head in the series of roads proximate the substantially non-horizontal print plane wherein the plurality of layers is supported by a receiving surface;
indexing the receiving surface substantially a thickness of a layer of the three-dimensional part; and
repeating the extruding step and the indexing step until the three-dimensional part is printed wherein a length of the three-dimensional part is greater than the first length of the build environment.
10. The method of claim 9 and wherein the build environment is subject to ambient conditions.
11. The method of claim 9 and further comprising:
heating the build environment.
12. The method of claim 9 and wherein the receiving surface comprises a rotatable belt.
13. The method of claim 9 and wherein the receiving surface comprises a starter piece having a surface substantially parallel to the printing plane.
14. An additive manufacturing system for printing a three-dimensional part, the system comprising:
a build environment having a first length;
a gantry located within the build environment;
a print head attached to the gantry, wherein the gantry is configured to move the print head in a plane substantially parallel to a print plane, wherein a part material is extruded in the print plane to print the three-dimensional part in a layer-by-layer manner, wherein the print plane is non-horizontal;
a closed looped belt configured to receive the printed part material from the print head to build the three-dimensional part in the layer-by-layer manner to a selected part length where the part length is greater than the first length of the build environment; and
a drive roller configured to index at least an upper portion of the closed looped belt substantially parallel to a printing axis such that the upper portion and at least a portion of the three-dimensional part move out of the build environment as the three-dimensional part is being built in the layer-by layer manner.
15. The system of claim 14 , wherein the build environment is unheated.
16. The system of claim 14 , wherein the build environment comprises one or more heaters configured to heat the build environment proximate the build plane.
17. The system of claim 14 , wherein the build environment comprises a chamber having chamber walls and a port, and wherein the indexing moves the receiving surface and at least a portion of the three-dimensional part through the port.
18. The system of claim 14 , wherein the build environment comprises a plurality of chambers in series, and wherein the indexing moves the receiving surface and at least a portion of the three-dimensional part through each of the plurality of chambers, wherein each of the plurality of chambers is configured to be heated to different temperatures to define a step-down temperature gradient.
19. The system of claim 14 , wherein the printing axis comprises a substantially non-vertical printing axis.
20. The system of claim 14 , and further comprising one or more post-printing processing stations, wherein the rotatable belt extends through the one or more post-printing processing stations.