US010494219B2

( 12 ) United States Patent (10 ) Patent No.: US 10,494,219 B2

Nadeau et al. (45 ) Date of Patent: Dec. 3 , 2019
(54 ) FILAMENT LOADING DRIVE IN A 3D (56 ) References Cited
PRINTER
U.S. PATENT DOCUMENTS
(71) Applicant: Stratasys, Inc. , Eden Prairie , MN (US) 4,461,416 A * 7/1984 Cheh B65H 51/10
(72 ) Inventors: Jordan Paul Nadeau, St. Louis Park , 226/1
MN (US ); Peter D. Schuller , Elko , MN 6,004,124 A 12/1999 Swanson et al.
6,722,872 B1 4/2004 Swanson et al.
(US ); Shawn Michael Koop, Blaine, 7,063,285 B1 6/2006 Turley et al.
MN (US); Logan R. Kiene , 7,127,309 B2 10/2006 Dunn et al .
Minneapolis , MN (US) 7,604,470 B2 10/2009 LaBossiere et al.
7,625,200 B2 12/2009 Leavitt
(73) Assignee : STRATASYS , INC., Eden Prairie , MN (Continued )
(US)
FOREIGN PATENT DOCUMENTS
( * ) Notice : Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 WO 2016014543 Al 1/2016
U.S.C. 154 (b ) by 387 days . Primary Examiner Jacob T Minskey
(21 ) Appl. No.: 15 /237,161 Assistant Examiner — Melody Tsui
(74 ) Attorney, Agent, or Firm — Westman , Champlin &
( 22 ) Filed : Aug. 15 , 2016 Koehler, P.A.
(65) Prior Publication Data (57) ABSTRACT
US 2018/0043628 A1 Feb. 15 , 2018 A 3D printer includes at least one consumable loading bay
(51) Int. Ci. configured to supply filament from a consumable supply
B33Y 30/00 ( 2015.01) assembly to a print head and at least one drive assembly that
B65H 51/10 ( 2006.01 ) is configured to advance filament to the print head from the
B33Y 40/00 (2015.01) consumable supply. Each drive assembly includes a follower
B651 51/32 ( 2006.01) wheel rotatable about a follower axis and a drive wheel
B29C 64/209 (2017.01) spaced apart from the follower wheel. The drive wheel is
B29C 64/321 ( 2017.01) rotatable about a drive axis and is located on an opposing
B29C 64/118 ( 2017.01) side of a filament path from the follower wheel such that the
(52 ) U.S. CI. follower axis and the drive axis are substantially parallel.
CPC B65H 51/10 (2013.01); B29C 64/118 The drive wheel further includes an outer surface extending
(2017.08 ); B29C 64/209 (2017.08); B29C between two ends and has at least one engaging portion that
64/321 (2017.08 ); B33Y 30/00 ( 2014.12 ); is configured to engage with the filament and at least one
B33Y 40/00 ( 2014.12 ); B65H 51/32 (2013.01) disengaging portion that is configured to disengage from the
(58 ) Field of Classification Search filament.
CPC B65H 51/10 ; B33Y 30/00 ; B33Y 40/00
See application file for complete search history . 12 Claims, 4 Drawing Sheets

--102 100

104 -109 110

-108
114 -116
112
118
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( 56 ) References Cited
U.S. PATENT DOCUMENTS
7,938,356 B2 5/2011 Taatjes et al.
8,403,658 B2 3/2013 Swanson
8,439,665
B2 5/2013 Batchelder et al.
8,985,497
B2 3/2015 Mannella et al.
9,073,263
B2 7/2015 Mannella et al.
9,108,360
B2 8/2015 Comb et al.
9,321,609
B2 4/2016 Koop et al.
2007/0228590 A1 * 10/2007 LaBossiere B33Y 30/00
264 /40.1
2014/0159273 A1 * 6/2014 Koop B65H 51/10
264/129
2015/0096717 A1 4/2015 Batchelder et al.
2015/0097053 A1 4/2015 Batchelder et al.
* cited by examiner
U.S. Patent Dec. 3 , 2019 Sheet 1 of 4 US 10,494,219 B2

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38
Computer 42

Controller 40

44

-12 16 12
16

18B
18A o
36 34
20 20
22
26 14 14

24
28

30

32

Fig. 1
U.S. Patent Dec. 3 , 2019 Sheet 2 of 4 US 10,494,219 B2

-102 100

110

-109
106
104 113
111
108
116
112
117
114
118 107
115
Fig. 2
U.S. Patent Dec. 3 , 2019 Sheet 3 of 4 US 10,494,219 B2

-102 100

terreno
104 -109 110
-108
114 -116
112
Fig . 3 -118
U.S. Patent Dec. 3 , 2019 Sheet 4 of 4 US 10,494,219 B2

-17

-118
-107
112

115 -116
114

Fig . 4

-17
-107
112

-116
115 118
114

Fig . 5
 US 10,494,219 B2
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FILAMENT LOADING DRIVE IN A 3D side of a filament path from the follower wheel such that the
PRINTER follower axis and the drive axis are substantially parallel.
The drive wheel further includes an outer surface extending
BACKGROUND between two ends. The outer surface has at least one
5 engaging portion that is configured to engage with the
The present disclosure relates to 3D printers for printing filament and at least one disengaging portion that is config
or otherwise producing three -dimensional (3D ) parts . In ured to disengage from the filament.
particular, the present disclosure relates to a filament drive In another aspect of the present disclosure , a 3D printer
for advancing filament from a consumable assembly to a includes a drive assembly configured to advance filament
print head feed drive in a 3D printer. 10
from a consumable supply to a print head . The drive
Additive manufacturing, also called 3D printing, is gen assembly includes a motor, a drive shaft rotatable about an
erally a process in which a three - dimensional (3D ) object is axis and powered by the motor, a drive wheel fixed to the
built by adding material to form a 3D art rather than drive shaft along the axis and configured to provide the
subtracting material as in traditional machining. One basic
operation of an 3D printer consists of slicing a three- 15 filament to the print head . The drivewheelincludes an outer
surface extending between first and second ends and having
dimensional computer model into thin cross sections, trans at least one engaging portion that is configured to engage
lating the result into two -dimensional position data , and with the filament and at least one disengaging portion that is
feeding the data to control equipment which manufacture a configured to disengage from the filament. The drive assem
three -dimensional structure in an additive build style . Addi
tive manufacturing entails many different approaches to the 20 bly further includes a sensor configured to sense when the at
method of fabrication, including fused deposition modeling, least one disengaging portion faces the filamentsuch that the
ink jetting, selective laser sintering , powder/binder jetting , drive wheel is spaced apart from the filament.
electron -beam melting, electrophotographic imaging, and In yet another aspect of the present disclosure , a method
stereolithographic processes. Using one or more additive of loading filament in a 3D printer is provided . A drive wheel
manufacturing techniques , a three -dimensional solid object 25 is configured to engage with a filament in a first direction to
of virtually any shape can be printed from a digital modelof advance the filament to a print head feed drive . The drive
the object by an 3D printer, commonly referred to as 3D wheel includes an outer surface extending between two ends
printer.
In a fused deposition modeling 3D printer , a printed part and having at least one engaging portion and at least one
may be printed from a digital representation of the printed 30 configured toportion
disengaging . The at least one engaging portion is
engage with the filament to drive the filament
part in an additive build style by extruding a flowable part
material along toolpaths. The part material is extruded toto the print head feed drive . The drive wheel is configured
through an extrusion tip carried by a print head of the in a position from
disengage
that
the filament by stopping the drive wheel
corresponds with the at least one disen
system , and is deposited as a sequence of roads onto a gaging portion facing the filament
substrate . The extruded part material fuses to previously drive wheel to be spaced apart fromandthethereby
35 causing the
filament.
deposited part material, and solidifies upon a drop in tem
perature . In a typical system where the material is deposited Definitions
in planar layers, the position of the print head relative to the
substrate is incremented along an axis (perpendicular to the Unless otherwise specified, the following terms as used
build plane ) after each layer is formed, and the process is 40 herein have the meanings provided below :
then repeated to form a printed part resembling the digital
representation . The terms “ preferred ” , “ preferably ” , “ example ” and
In fabricating printed parts by depositing layers of a part “ exemplary ” refer to embodiments of the invention thatmay
material, supporting layers or structures are typically built afford certain benefits , under certain circumstances . How
underneath overhanging portions or in cavities of printed 45 ever , other embodiments may also be preferred or exem
parts under construction ,which are not supported by the part plary, under the same or other circumstances. Furthermore ,
material itself. A support structure may be built utilizing the the recitation of one or more preferred or exemplary
same deposition techniques by which the part material is embodiments does not imply that other embodiments are not
deposited . A host computer generates additional geometry useful, and is not intended to exclude other embodiments
acting as a support structure for the overhanging or free- 50 from the scope of the present disclosure.
space segments of the printed part being formed . Support Directional orientations such as “ above” , “ below ” , “ top ” ,
material is then deposited from a second nozzle pursuant to “ bottom ” , and the like are made with reference to a layer
the generated geometry during the printing process . The printing direction of a 3D part. In the embodiments shown
support material adheres to the part material during fabri below , the layer-printing direction is the upward direction
cation , and is removable from the completed printed part 55 along the vertical z -axis . In these embodiments , the terms
when the printing process is complete . “ above ” , “below ” , “ top ” , “bottom ” , and the like are based on
the vertical z -axis. However, in embodiments in which the
SUMMARY layers of 3D parts are printed along a different axis , such as
along a horizontal x -axis or y -axis , the terms “ above” ,
An aspect of the present disclosure includes a 3D printer 60 “ below ” , “ top ”, “ bottom ” , and the like are relative to the
having at least one consumable supply configured to supply given axis.
filament to a print head and at least one drive assembly for The term “ providing ” , such as for providing a material”,
advancing filament to a print head feed drive from the when recited in the claims, is not intended to require any
consumable supply . Each drive assembly includes a follower particular delivery or receipt of the provided item . Rather ,
wheel rotatable about a follower axis and a drive wheel 65 the term “ providing” is merely used to recite items that will
spaced apart from the follower wheel. The drive wheel is be referred to in subsequent elements of the claim (s), for
rotatable about a drive axis and is located on an opposing purposes of clarity and ease of readability .
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3 4
Unless otherwise specified , temperatures referred to filament or otherwise lets the filament pass freely. In some
herein are based on atmospheric pressure ( i.e. one atmo embodiments, each disengaging portion is a planar or flat
sphere ) portion .
The terms “ about” and “ substantially ” are used herein The present disclosure may be used with any suitable
with respect to measurable values and ranges due to 5 extrusion -based 3D printer. For example, FIG . 1 illustrates
expected variations known to those skilled in the art ( e.g., a 3D printer 10 that has a substantially horizontal print plane
limitations and variabilities in measurements ). where the part being printed is indexed in a substantially
vertical direction as the part is printed in a layer-by -layer
BRIEF DESCRIPTION OF THE DRAWINGS manner using at least one print head . For example , in FIG .
10
1 , 3D printer 10 includes two print heads 18A , 18B and two
FIG . 1 is a block diagram of a 3D printer configured to consumable assemblies 12 , where each consumable assem
print 3D parts and support structures as described in the bly 12 is an easily loadable , removable , and replaceable
present disclosure . container device that retains a supply of a consumable
FIG . 2 is a simplified perspective view of a drive assem 15 filament for printing with 3D printer 10. Typically, one of the
bly for feeding filament to a print head in a 3D printer consumable assemblies 12 contains a partmaterial filament,
according to one embodiment. and the other consumable assembly 12 contains a support
FIG . 3 is a more detailed section view of a drive assembly material filament, each supplying filament to one print head
for feeding filament to a print head in a 3D printer according 18A or 18B . However, both consumable assemblies 12 may
to one embodiment. 20 be identical in structure . Each consumable assembly 12 may
FIG . 4 is a schematic diagram illustrating the drive retain the consumable filament on a wound spool, a spool
assembly illustrated in FIGS. 2 and 3 in an engaged position less coil, or other supply arrangement, such as discussed in
with a filament. Swanson et al., U.S. Pat. No. 8,403,658; Turley et al. U.S.
FIG . 5 is a schematic diagram illustrating the drive Pat . No. 7,063,285 ; Taatjes at al., U.S. Pat . No. 7,938,356 ;
assembly illustrated in FIGS. 2 and 3 in a disengaged 25 and Mannella et al., U.S. Pat . Nos. 8,985,497 and 9,073,263 .
position with a filament. Each print head 18A and 18B is an easily loadable,
removable and replaceable device comprising a housing that
DESCRIPTION retains a liquefier assembly 20 having a nozzle tip 14. Each
print head 18A and 18B is configured to receive a consum
Described herein are embodiments of a filament loading 30 able material, melt the material in liquefier assembly 20 to
drive assembly for advancing filament from a consumable produce a molten material, and deposit the molten material
supply to a feed drive at or near a print head in extrusion from a nozzle tip 14 of liquefier assembly 20. Examples of
based additive manufacturing devices. When the filament suitable liquefier assemblies for print head 18 include those
advanced from the filament loading drive reaches the feed disclosed in Swanson et al., U.S. Pat. No.6,004,124 ; LaBos
drive , the loading drive assembly is positioned in a manner 35
siere , et al., U.S. Pat. No. 7,604,470 ; Leavitt, U.S. Pat. No.
that releases its grip on the filament, allowing the feed drive
7,625,200 ; and Batchelder et al., U.S. Pat. No. 8,439,665.
to take over. Other suitable liquefier assemblies include those disclosed in
In additive manufacturing devices that have multiple U.S. Patent Publications Nos . 2015/0096717 and 2015 /
filament drives acting on the same filament strand, such as 0097053 ; and in PCT publication No. WO2016014543A .
a loading drive at the consumable supply and a feed drive at 40 Guide tube 16 provide a path interconnecting consumable
or near the print head , if one drive runs faster than the other,
assembly 12 and print head 18A or 18B , where a filament
filament may be pushed into the printer (such as in a feed feed drivemechanism of printhead 18A or 18B (or of printer
tube), causing buckling and high friction. Likewise, if one of
10 ) engages the filament and draws successive segments of
the drives runs too slow , there may be a high pull force , the consumable filament from consumable assembly 12 ,
which causes strain on the motors and results in loss of 45 through guide tube 16 , to liquefier assembly 20 of print head
extrusion . Therefore , it is beneficial if the drive for loading
18A or 18B . The filament feed drive may be a high -margin
filament into the printer is not in contact with the filamentdrive as described in U.S. Pat. No. 6,004,124, or U.S. Pat.
when an additive manufacturing device is building a part. No.9,321,609 , or any type of drive mechanism for engaging
Some drives deal with this issue by using software and and controllably feeding filament into the printhead as a part
making calibrations during manufacture to get the timing 50 is printed . In this embodiment, guide tube 16 may be a
correct . Other drives include complex mechanisms for mov component of 3D printer 10 , rather than a sub- component of
ing the drive away from the filament including extra motors consumable assemblies 12. In other embodiments , guide
and solenoids, such as is described in U.S. Pat. No. 7,374 , tube 16 is a sub - component of consumable assembly 12 , and
712. The drive assembly as described herein simplifies the may be interchanged to and from 3D printer 10 with each
driving of filament and eliminates the above issues and 55 consumable assembly 12. In alternate embodiments, guide
complexities. tube 16 may be replaced with another structure or feature
In accordance with this disclosure , the drive assembly for that functions to guide a filament strand through the printer.
loading filament into a 3D printer includes at least one During a build operation , the successive segments of con
engaging portion or segment and at least one disengaging sumable filament that are driven into print head 18A or 18B
portion or segment. In this way, when the engaging portion 60 are heated and melt in liquefier assembly 20. The melted
of the drive wheel is oriented to face the filament and the material is extruded through nozzle tip 14 in a layer wise
filament path , the drive wheel engages with the filament and pattern to produce printed parts .
filament is driven to the head . In some embodiments each 3D printer 10 prints parts or models and corresponding
engaging portion is toothed to increase the traction between support structures ( e.g., 3D part 22 and support structure 24 )
the drive and the filament. When the disengaging portion of 65 from the part and supportmaterial filaments, respectively , of
the drive wheel is oriented to face the filament and the consumable assemblies 12 , using a layer-based , additive
filament path , the drive wheel is disengaged from the manufacturing technique. Suitable 3D printers 10 include
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5 6
fused deposition modeling systems developed by Stratasys, and head carriage 34 (and print heads 18A and 18B ) may be
Inc., Eden Prairie, Minn . under the trademark “ FDM .” configured to move along the z - axis. Other similar arrange
As shown , 3D printer 10 includes system casing 26 , ments may also be used such that one or both of platen 30
chamber 28 , platen 30 , platen gantry 32, head carriage 34 , and print heads 18A and 18B are moveable relative to each
and head gantry 36. System casing 26 is a structural com 5 other . Platen 30 and head carriage 34 (and print heads 18A
ponent of 3D printer 10 and may include multiple structural and 18B ) may also be oriented along different axes. For
sub -components such as support frames, housing walls , and example , platen 30 may be oriented vertically and print
the like. In some embodiments, system casing 26 may heads 18A and 18B may print 3D part 22 and support
include container bays configured to receive consumable structure 24 along the x -axis or the y -axis.
assemblies 12. In alternative embodiments , the container 10 3D printer 10 also includes controller assembly 38 , which
bays may be omitted to reduce the overall footprint of 3D may include one or more control circuits (e.g., controller 40)
printer 10. In these embodiments , consumable assembly 12 and/ or one or more host computers ( e.g., computer 42 )
may stand proximate to system casing 26 , while providing configured to monitor and operate the components of 3D
sufficient ranges ofmovement for guide or feed tubes 16 and printer 10. For example, one or more of the control functions
print heads 18 that are shown schematically in FIG . 1 . 15 performed by controller assembly 38 , such as performing
Chamber 28 is an enclosed environment that contains move compiler functions, can be implemented in hardware ,
platen 30 for printing 3D part 22 and support structure 24 . software, firmware , and the like , or a combination thereof ;
Chamber 28 may be heated (e.g., with circulating heated air) and may include computer -based hardware , such as data
to reduce the rate at which the part and support materials storage devices, processors , memory modules , and the like,
solidify after being extruded and deposited (e.g., to reduce 20 which may be external and/or internal to 3D printer 10 .
distortions and curling ). In alternative embodiments, cham Controller assembly 38 may communicate over commu
ber 28 may be omitted and/or replaced with different types nication line 44 with print heads 18A and 18B , chamber 28
of build environments . For example , 3D part 22 and support (e.g., with a heating unit for chamber 28 ), head carriage 34,
structure 24 may be built in a build environment that is open motors for platen gantry 32 and head gantry 36 , and various
to ambient conditions or may be enclosed with alternative 25 sensors , calibration devices, display devices, and /or user
structures ( e.g., flexible curtains). input devices . In some embodiments, controller assembly 38
Platen 30 is a platform on which 3D part 22 and support may also communicate with one ormore of platen 30, platen
structure 24 are printed in a layer -by - layer manner, and is gantry 32, head gantry 36 , and any other suitable component
supported by platen gantry 32. In some embodiments , platen of system 10. While illustrated as a single signal line ,
30 may engage and support a build substrate, which may be 30 communication line 44 may include one or more electrical,
a tray substrate as disclosed in Dunn et al., U.S. Pat. No. optical, and /or wireless signal lines, which may be external
7,127,309, fabricated from plastic , corrugated cardboard , or and /or internal to system 10 , allowing controller assembly
other suitable ma al, and may also include a flexible 38 to communicate with various components of system 10 .
polymeric film or liner, tape, or other disposable fabrication During operation , controller assembly 38 may direct
for adhering deposited material onto the platen 30 or onto 35 platen gantry 32 to move platen 30 to a predetermined height
the build substrate . Platen gantry 32 is a gantry assembly within chamber 28. Controller assembly 38 may then direct
configured to move platen 30 along ( or substantially along) head gantry 36 to move head carriage 34 (and the retained
the vertical z - axis . printheads 18A and 18B ) around in the horizontal x -y plane
Head carriage 34 is a unit configured to receive and retain above chamber 28. Controller assembly 38 may also direct
one or both print heads 18A and 18B , and is supported by 40 the filamentfeed drives associated with print heads 18A and
head gantry 36. Head carriage 34 preferably retains each 18B to selectively draw successive segments of the consum
print head 18A and 18B in a manner that prevents or restricts able filaments from consumable assemblies 12 and through
movement of the print head 18 relative to head carriage 34 guide tubes 16 , respectively, to be extruder by print heads
so that nozzle tip 14 remains in the x -y build plane, but 18A and 18B .
allows nozzle tip 14 of the print head 18 to be controllably 45 While FIG . 1 illustrates a 3D printer 10 where a build
moved out of the x -y build plane through movement of at plane is in a substantially horizontal x -y plane and the platen
least a portion of the head carriage 34 relative the x -y build 30 is moved in a z direction substantially normal to the
plane (e.g., servoed , toggled , or otherwise switched in a substantially horizontal x -y build plane, the present disclo
pivoting manner). In further embodiments , printheads 18A sure is not limited to a 3D printer 10 as illustrated in FIG .
and 18B and corresponding head carriage 34 may optionally 50 1.
be retrofitted into an existing system 10 . FIG . 2 is a simplified perspective view of a drive assem
In the shown embodiment, head gantry 36 is a robotic bly 100 for loading filament from consumable supply 12 to
mechanism configured to move head carriage 34 (and the print head 18A or 18B in 3D printer 10 according one
retained print heads 18A and 18B ) in (or substantially in ) a embodiment. FIG . 3 is a more detailed section view of drive
horizontal x -y plane above platen 30. Examples of suitable 55 assembly 100 for loading filament from consumable supply
gantry assemblies for head gantry 36 include those disclosed 12 to print head 18A and 18B in 3D printer 10 according to
in Swanson et al., U.S. Pat. No. 6,722,872; and Comb et al.,
one embodiment. Drive assembly 100 includes a motor 102,
U.S. Pat. No. 9,108,360 , where head gantry 36 may also gear train 104 , a rotatable drive shaft 106 located along a
support deformable baffles (not shown ) that define a ceiling
drive axis 107 and powered by motor 102 , an encoder wheel
for chamber 28. Head gantry 36 may utilize any suitable 60 108 fixed to drive shaft 106 , an optical sensor 110 , a drive
bridge - type gantry or robotic mechanism for moving head wheel 112 fixed to shaft 106 and a follower wheel 114
carriage 34 (and the retained print heads 18 ), such as with located separately from shaft 106 along a follower axis 115 .
one or more motors (e.g. , stepper motors and encoded DC Follower wheel 114 is rotatable about follower axis 115 and
motors), gears, pulleys , belts , screws, robotic arms, and the follower wheel 114 is spaced apart from drive wheel 112. In
like. 65 particular, drive wheel 112 is located on an opposing side of
In an alternative embodiment, platen 30 may be config a filament path such that drive axis 107 and follower axis
ured to move in the horizontal x -y plane within chamber 28 , 115 are substantially parallel.
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As illustrated in FIGS . 2 and 3 , drive wheel 112 comprises and torque at which drive wheel 112 is moving and the fact
an outer surface 111 that extends between a first end 113 and that the filament is not engaged with the print head drive ,
a second end 117. In other words, drive wheel 112 is similar , does not adversely affect the feed of filament to the print
butdifferent to the basic shape of a cylinder where a cylinder head .
has a first circular end , a second circular end and an outer 5 However, when the filament reaches the print head and the
arcuate surface therebetween . Like a cylinder, drive wheel filament is engaged by a filament feed drive mechanism at
112 includes at least one engaging portion or arcuate portion the print head , then motor 112 is turned off by a controller,
116 that may include a plurality of teeth on outer surface 111 . such as controller assembly 38 , which stops drive wheel 112
Unlike a cylinder, drive wheel 112 includes at least one from rotating. When stopped , drive wheel 112 needs to be
disengaging portion or planar or flat portion 118. Although 10 oriented in a position where it is disengaged from the
drive wheel 112 includes the at least one disengaging portion filament. This means the controller orients drive wheel 112
118 , drive wheel 112 , when continuously rotated is capable so that planar or flat portion 118 faces filament 17. To
of driving the filament using the at least one engaging accomplish this , drive assembly 112 includes sensor 110 ,
portion 116 . which in the illustrated embodiment is an optical sensor 110 .
In the embodiment illustrated in FIGS. 2 and 3 , drive 15 Sensor 110 senses when at least one planar or flap portion
wheel 112 includes only one engaging or arcuate portion 116 118 faces the filament and drive wheel 112 , sends this
and , in particular, engaging portion 116 follows an outer information to the controller and the controller moves drive
curved surface of a cylinder. In the embodiment illustrated wheel 112 so that flat or planar portion 118 faces filament 17
in FIGS. 2 and 3 , drive wheel 112 includes only one and therefore disengages from the filament 17.
disengaging or flat portion 118 , which is a slice made 20 In the embodiment illustrated , encoder wheel 108 , which
through the cylindrical shape. The slice is made substantially is fixed to shaft 106 and spaced apart from drive wheel 112 ,
parallel with drive axis 107 and therefore off -center from includes a slot 109. Slot 109 extends along a portion of a
drive axis 107 thus giving drive wheel 112 a D - shape, where radius of encoder wheel 108 and is positioned or located on
the arcuate portion 116 of the D is optionally toothed and the encoder wheel 108 substantially perpendicular to planar or
straight portion of the D is the planar or flat portion 118. In 25 flat portion 118 and opposite from flat portion 118 with
other words, each disengaging portion 116 of outer surface respect to drive shaft 106 and drive axis 107.More specifi
111 of drive wheel 112 is located a same radial distance from cally , optical sensor 110 senses slot 109 as being in a
drive axis 107 and wherein each disengaging portion 118 is position that denotes that the at least one planar or flat
located a varying distance from drive axis 107. portion 118 of drive wheel 112 is disengaged from the
However , it should be realized that other embodiments 30 filament. Drive assembly 100 uses the sensed information
with respect to shape are possible . For example, drive wheel from optical sensor 110 to orient drive wheel 112 in this
112 can be of an extruded triangle shape , where each corner position .
of the triangle is an engaging portion with optional teeth and In some instances, it is desirable to retract the filament 17
each leg of the triangle is a disengaging portion that is flat from the print head 18A or 18B such as when the filament
or planar. In this case , the drive wheel would include three 35 in the consumable assembly 12 is depleted . To retract the
engaging portions and three disengaging portions. In another filament 17 from the print head 18A or 18B , the drive wheel
example , drive wheel 112 can be of an extruded polygon , 112 is moved in a second rotational direction , opposite the
such as an extruded hexagon or an extruded octagon shape , first rotational direction . Once the filament 17 is retracted
where each corner of the polygon is an engaging portion from the print head 18A or 18B , the consumable assembly
optionally having teeth and each leg of the extruded polygon 40 12 can be removed and /or replaced . Alternatively, the drive
is a disengaging portion that is flat or planar. In this case, the wheel 112 is moved in the second rotational direction until
drive wheel 112 would include six engaging portions and six the filament 17 is retracted into or near the consumable
disengaging portions for an extruded hexagon shape and assembly 12 .
eight engaging portions and eight disengaging portions for Although the subject of this disclosure has been described
an extruded octagon shape. 45 with reference to several embodiments , workers skilled in
FIG . 4 is a schematic diagram illustrating drive wheel 112 the art will recognize that changesmay be made in form and
in an engaged position with a filament. FIG . 5 is a schematic detail without departing from the spirit and scope of the
diagram illustrating drive wheel 112 in a disengaged posi disclosure . In addition , any feature disclosed with respect to
tion with a filament. Both FIGS . 2 and 3 illustrates drive one embodiment may be incorporated in another embodi
wheel 112 in a disengaged position . During operation , motor 50 ment, and vice -versa .
102 provides the power to rotate drive shaft 106 via gear What is claimed is:
train 104 , which then rotates drive wheel 112 to drive a 1. A 3D printer comprising :
filament up to a print head . In particular, engaging portion a drive assembly configured to advance filament from a
116 of drive wheel 112 grabs or engages filament against consumable loading bay to a print head , the drive
follower wheel 114 and uses follower wheeler 114 , which 55 assembly comprising :
opposes drive wheel 112 , to create a frictional engagement a motor;
to ensure the filament is advanced at a desirable rate with a drive shaft rotatable about a fixed axis and being
substantially no slippage . powered by the motor;
In FIG . 4 , engaging portion 116 of drive wheel 112 is a drive wheel comprises a shape of a letter D and
engaged with filament 17 and therefore drives filament to a 60 having an engaging portion and a disengaging por
print head through rotation of the drive wheel 112 in a first tion ,wherein the engaging portion of the drive wheel
rotational direction . In FIGS . 2 , 3 and 5 , drive wheel 112 is comprises an arcuate portion of the shape of the
disengaged from filament 17 and therefore is not driving the letter D wherein the arcuate portion comprises a
filament to print head . Therefore , when motor 102 continu plurality of teeth and wherein the disengaging por
ously rotates drive wheel 112 , drive wheel 112 is not 65 tion of the drive wheel comprises a straight portion
continuously being engaged with the filament during driv of the shape of the letter D wherein the disengaging
ing , but the resulting drive of filament, because of the speed portion is substantially flat, wherein the drive wheel
 US 10,494,219 B2
9 10
is fixed to the drive shaft and rotatable about the disengaging the drive wheel from the filament when the
fixed axis of the drive shaft and configured to feed filament reaches the print head feed drive by stopping
the filament to the print head , wherein the engaging the drive wheel in a position that corresponds with the
portion is configured to engage with the filament as at least one disengaging portion facing the filament and
the drive wheel is rotated and the disengaging por 5 thereby causing the drive wheel to be spaced apart from
the filament.
tion is configured to disengage from the filament as 8. The method of claim 7, wherein disengaging the drive
the drive wheel is rotated ; and wheel from the filament by stopping the drive wheel in the
a sensor configured to sense when the at least one position that corresponds with the at least one disengaging
disengaging portion faces the filament such that the 10 portion facing the filament comprises sensing that the at
drive wheel is spaced apart from the filament. least one disengaging portion of the drive wheel is in a
2. The 3D printer of claim 1, wherein the sensor com position that faces the filament.
prises an encoder wheel fixed to the drive shaft along the 9. The method of claim 8 , wherein sensing the at least one
axis and spaced apart from the drive wheel. disengaging portion of the drive wheel is in the position that
3. The 3D printer of claim 2 , wherein the sensor further 15 faces the filament comprises sensing with an optical sensor
comprises an optical sensor that senses a position of the an encoder wheel that includes a slot in a position that is
encoder wheel that is indicative of the at least one disen known relative to the at least one disengaging portion .
gaging portion facing the filament and therefore the drive 10. The method of claim 7 , and further comprising
wheel as being spaced apart from the filament. engaging the drive wheel with the filament in a second
4. The 3D printer of claim 2 , wherein the encoder wheel 20 direction to retract the filament from the print head feed
drive .
comprises a slot that is located substantially perpendicular to 11. The 3D printer of claim 1 and further comprising :
the at least one disengaging portion of the drive wheel and a follower wheel rotatable about a fixed follower axis
on an opposing side of the drive shaft from the at least one wherein the follower wheel is spaced from the drive
disengaging portion of the drive wheel. wheel such that the follower wheel and the engaging
5. The 3D printer of claim 4 , wherein the sensor com 25 portion of the drive wheel counter-rotate and engage
prises an optical sensor that senses the position of the slot in opposing sides of the filament to drive the filament.
the encoder wheel to determine the position of the at least 12. A 3D printer comprising :
one disengaging portion of the drive wheel . a drive assembly configured to advance filament from a
6. The 3D printer of claim 1, further comprising a consumable loading bay to a print head , the drive
controller configured to stop the drive assembly in a position 30 assembly comprising :
where the at least one disengaging portion faces the filament a motor ;
and thereby is spaced apart from the filament when the a drive shaft rotatable about a fixed axis and being
filament reaches the print head . powered by the motor;
7. A method of loading filament into a 3D printer, the a drive wheel fixed to the drive shaft and rotatable
method comprising: 35
engaging a drive wheel with a filament in a first direction about the fixed axis and configured to feed the
to advance the filament to a print head feed drive by filament to the print head , wherein the drive wheel
rotating the drive wheel about a fixed axis, the drive includes an outer surface extending between first and
wheel including an outer surface comprising a shape of second ends and having an engaging portion config
a letter D and having an engaging portion and a 40 ured to engage with the filament as the drive wheel
disengaging portion , wherein the engaging portion of is rotated and a disengaging portion configured to
the drive wheel comprises an arcuate portion of the disengage from the filament as the drive wheel is
shape of the letter D wherein the arcuate portion rotated ; and
comprises a plurality of teeth and wherein the disen a sensor configured to sense when the disengaging portion
gaging portion of the drive wheel comprises a straight 45 faces the filament such that the drive wheel is spaced
portion of the shape of the letter D wherein the disen apart from the filament;
gaging portion is substantially flat, wherein the engag wherein the drive wheel comprises a shape of a letter D ,
ing portion engages with the filament as the drive wheel wherein the engaging portion comprises an arcuate
is rotated about the fixed axis to drive the filament to portion of the D and has a plurality of teeth and the
the print head feed drive and wherein the disengaging 50 disengaging portion comprises a straight, flat portion of
portion disengages from the filament as the drive wheel the letter D.
is rotated about the fixed axis; and