Granted Patent B2

US 12,570,042 · App. 17/417,038 · Granted Mar 10, 2026

Inventors: Scott Klimczak (St. Petersburg, FL); Luke Rodgers (St. Petersburg, FL); Darin Burgess (St. Petersburg, FL)

B29C64/209B33Y30/00B29C64/393B33Y50/02

Abstract

Claims (45)

1 . A print head to increase an engagement length on a print filament for enhanced grip of the print filament for additive manufacturing, comprising:

a first hob comprising a first diameter greater than 20 mm;

a second hob comprising a second diameter greater than 20 mm;

wherein each hob comprises two halves;

an adjustable shim configured to reposition at least one of the first hob and the second hob to modify grip on the print filament between the first hob and the second hob, wherein the adjustable shim is generally disposed between the two halves of the first hob or the second hob;

wherein the first diameter and the second diameter are arranged to fit a 1.75 mm print material filament between the first and second hobs;

at least one motor; and

at least one output nozzle having a heater to partially liquefy the print filament, wherein the at least one motor is operatively coupled to at least one of the first and second hobs to drive the print filament past the heater and through the at least one output nozzle upon the at least partial liquefication to provide the additive manufacturing, wherein the first diameter of the first hob and the second diameter of the second hob each comprise less than 40 mm.

2 . A print head for additive manufacturing, comprising:

a controller comprising a print plan to execute the additive manufacturing;

two proximate hobs each comprising a diameter of greater than 15 mm and being arranged, based on their respective diameters, so as to grip and drive a 1.75 mm print filament, wherein each hob comprises two halves;

an adjustable shim configured to modify a grip of the two proximate hobs, wherein the adjustable shim is generally disposed between the two halves of at least one of the two proximate hobs;

at least one motor communicatively coupled with the controller and capable of imparting a rotation to a respective one of the two hobs to drive the print filament, wherein an extrusion of a partial liquefication of the print filament ultimately results from the rotation; and

an interface to a liquefier capable of the partial liquefication by at least one nozzle heater for output of the partial liquefication as the additive manufacturing;

wherein the controller is configured to receive feedback from the at least one motor,

wherein the controller is configured to modify rotation of the respective one of the two hobs based on the print plan and the feedback received from the at least one motor, and

wherein the modified rotation of the respective one of the two hobs consequently modifies movement of the print filament.

3 . The print head of claim 2 , further comprising a force adjuster configured to increase a contact area of at least one of the two hobs on the print filament.

4 . The print head of claim 2 , wherein the hobs further comprise a grip area configured to mate around the print filament.

5 . The print head of claim 2 , wherein the controller is communicatively coupled with an X-Y axis positional driver capable of positioning the print head, and wherein the controller coordinates operation of the at least one motor with the X-Y axis positional driver based at least on motor performance and the print plan.

6 . The print head of claim 2 , wherein the controller receives the feedback regarding the additive manufacturing from an encoder of the at least one motor.

7 . The print head of claim 2 , wherein the modification comprises a variation in operation of the at least one motor, wherein the variation comprises a rotation rate.

8 . The print head of claim 7 , wherein the variation further comprises one of an acceleration and a deceleration of the rotation rate of the at least one motor.

9 . The print head of claim 2 , wherein the at least one motor comprises a stepper motor.

10 . The print head of claim 2 , wherein the diameter of the hobs provides enhanced force on the print filament to push through an inlet plug at the interface.

11 . The print head of claim 2 , further comprising at least one encoder associated with each motor of the at least one motor.

12 . The print head of claim 2 , further comprising at least one sensor that senses at least one of the at least one motor, the hobs and the interface.

13 . The print head of claim 2 , wherein the controller receives the feedback regarding the additive manufacturing from a current of the at least one motor.

14 . The print head of claim 2 , wherein the controller receives the feedback regarding the additive manufacturing from a sensor of the at least one motor.

15 . The print head of claim 2 , wherein the rotation of the arranged two proximate hobs is capable of imparting a drive force of at least 30 lbs.

16 . The print head of claim 2 , wherein the two proximate hobs are provided in a first set with a first diameter, and wherein a second set of two proximate hobs with a second diameter are configured to replace the first set of two proximate hobs.

17 . A print head to increase an engagement length on a print filament for enhanced grip of the print filament for additive manufacturing, comprising:

a controller comprising a print plan to execute the additive manufacturing;

a first hob comprising a first diameter greater than 20 mm;

a second hob comprising a second diameter greater than 20 mm;

wherein each hob comprises two halves;

wherein the first diameter and the second diameter are arranged to fit a 1.75 mm print material filament between the first and second hobs;

an adjustable shim configured to reposition at least one of the first hob and the second hob to modify grip on the print filament between the first hob and the second hob, wherein the adjustable shim is generally disposed between the two halves of the first hob or the second hob;

at least one motor; and

at least one output nozzle having a heater to partially liquefy the print filament, wherein the at least one motor is operatively coupled to at least one of the first and second hobs to drive the print filament past the heater and through the at least one output nozzle upon the at least partial liquefication to provide the additive manufacturing, wherein the controller detects a change in the print plan indicative of needed variation in the drive to comport with the print plan.

18 . The print head of claim 17 , wherein the at least one motor consists of a first motor and a second motor, wherein the first motor drives the first hob and the second motor drives the second hob, and wherein the controller controls at least one of the first motor and the second motor based on at least one of:

motor feedback received from the first motor and the second motor,

the print plan,

a desired print resolution, and

a difference between at least one of current and desired position and speed of an X-Y axis positional driver.

Assignments (2)

Continuity (2)

References Cited (51)