DESC: FORM 2

THE PATENTS ACT 1970
[39 OF 1970]
&
The Patents Rules, 2003

COMPLETE SPECIFICATION
[See section 10 and rule 13]

TITLE: “ A SYSTEM FOR TESTING MIX DESIGN OF PRINT MATERIAL USED FOR THREE DIMENSION PRINTING IN CONSTRUCTION”

NAME AND ADDRESS OF THE APPLICANT:

TVASTA MANUFACTURING SOLUTIONS PRIVATE LIMITED of 5/1, 2nd Main, National HBCS, Plan-2, Prashanth Nagar, Bengaluru – 560079, Karnataka, India.

Nationality: INDIAN

The following specification describes the invention.
TECHNICAL FIELD

The present disclosure, in general, relates to the field of manufacturing. Particularly, but not limiting to, the present disclosure relates to printing of structures by employing a three-dimensional printer. Further, embodiments of the present disclosure disclose three-dimensional printing test module, for testing print material.

BACKGROUND

Civil construction has evolved over time. Conventionally, constructing a simple design, such as a two or three storied building, would take about 12 to 14 months’ time. Such long construction periods had several reasons. Some of the reasons may be lack of skilled labor, long set-in period of the concrete material used at the time and most importantly weather-related delays. With the advent of modern manufacturing, method of constructing structures have been enhanced or improved predominantly by considering the factors including, but not limited to, rate of construction, quality of constructions, resource management, and the like. In the recent past, there has been a rise in the demand for constructing structures having various dimensions and complex designs. Such complex constructional requirements are met by employing large-scale three-dimensional printers. The three-dimensional printers have introduced modern methodology of constructing various complicated and unique structures. The three-dimensional printers provide flexibility for novel and original constructional designs that may be explored, contrary to antiquated method of construction.

Generally, the conventional three-dimensional printers incorporate a print material, which may be laid or printed in a defined pattern, to form the structures. The print material may generally consist of a matrix and a binder. The matrix may have fine or coarse granules, while the binder may be adaptably added to hold the granules of the matrix together. The composition of the print material formed may be defined to be printable or may be pumped to flow at a specific rate. This way, the print material formed may be suitably fed to the conventional three-dimensional printer for printing, i.e. producing multiple layers in the defined pattern to form the structures having defined dimension or shape.

Further, consistency of the print material may vary in accordance with several factors including, but not limited to, temperature, humidity, quality of binder, evenness in size of the matrix, variation in composition, and the like. These factors may affect characteristics of the print material including, but not limited to, viscosity, adhesiveness, cohesiveness, and the like. Due to this variation in characteristics, the quality of structures printed may be affected. Also, the print material may be required to be produced in batches with a defined interval of time period, in order to allow previously printed layers to attain sufficient quality of dryness and rigidity. During this time period and due to the abovementioned factors, it may be difficult to maintain consistency in characteristics of the print material. Also, it may not be advisable to print the structure from the print material produced in batches having no knowledge of variations in characteristics and consistency from that of the previously produced print material. In conventional practice, the inconsistencies in the print material are noticed manually and may then be modified by varying the composition of the print material. Such method is not desirable and manual error may still persist.

With these variations in characteristics of the print material, there is a need to maintain and regulate consistency of the print material produced in each batch for printing and forming of the structures. The present disclosure is directed to overcome one or more limitations stated above.

SUMMARY

One or more shortcomings of the conventional three-dimensional printer are overcome, and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure, a system for testing print material used for three-dimensional printing is disclosed. The system includes a work bed and a 3Dprinter assembly. The assembly is configured to print a plurality of layers of the print material which are to be tested on the work bed. The system further includes a plurality of sensors mounted at pre-determined positions on the three-dimensional printer assembly, where the plurality of sensors are configured to sense parameters including extrudability, viscosity and workability of the print material. Further, the system includes a controller which is communicatively coupled with the plurality of sensors, where the controller is configured to receive the parameters of the print material sensed by the plurality of sensors. The controller also compares the received parameters of the print material with a pre-determined set of parameters to determine variation in consistency of the print material.

In an embodiment of the present disclosure, the plurality of sensors include a pressure sensor positioned at an outlet of a pumping unit. The pressure sensor is configured to detect pressure with which the print material is pumped from a pumping unit, wherein the pressure detected is indicative of extrudability and viscosity of the print material.

In an embodiment of the present disclosure, the pumping unit comprises of a primer unit and a pump for pumping the print material.

In an embodiment of the present disclosure, the plurality of sensors include a flow rate sensor positioned proximal to an outlet port of the nozzle. The flow rate sensor is configured to detect flow rate of the print material, where the flow rate detected is indicative of viscosity of the print material.

In an embodiment of the present disclosure, the plurality of sensors include a proximity sensor positioned proximal to the nozzle and the proximity sensor is configured to determine the compression of at least one layer of print material extruded on to the work bed.

In an embodiment of the present disclosure, an indication unit communicatively coupled with the controller is provided. Further, the controller is configured to indicate variation in the consistency of the print material through the indication unit, based on the comparison.

In an embodiment of the present disclosure, the indication unit is at least one of an audio and visual indicator.

In an embodiment of the present disclosure, the three-dimensional printer assembly comprises of a pumping unit adapted to receive the print material and pump the print material. Further, a nozzle is connected to the pumping unit, where the nozzle prints a plurality of layers of the print material on the work bed. Also, a traversing mechanism configured to selectively regulate movement of the nozzle, where the traversing mechanism is communicatively coupled to the controller, and the controller is configured to selectively control operation of the traversing mechanism.

In an embodiment of the present disclosure, the traversing mechanism includes a locomotion unit provided on either sides of the work bed, where the locomotion unit includes of a first set of rails and a second set of rails. Further, a support frame is slidably connected to the first set of rails, where the support frame is coupled to an actuator to impart movement of the nozzle in a longitudinal direction. Also, a second set of rails are positioned perpendicular to the first set of rails configured to accommodate a linear guide member holding the nozzle, where the linear guide member is coupled to at least one actuator for imparting movement of the nozzle in at least one of lateral and transverse directions.

In an embodiment of the present disclosure, the locomotion unit is at least one of a rack and pinon arrangement and a set of rails provided on either sides of the work bed.

In an embodiment of the present disclosure, the movement of the linear guide member along the second set of rails facilitates the movement of the nozzle along the lateral direction.

In another non-limiting embodiment of the present disclosure, a method for testing parameters of print material is disclosed. The method discloses of printing a plurality of layers of print material on a work bed by a three-dimensional printer assembly. Further, a plurality of parameters including at least one of extrudability and workability of the print material are sensed by a plurality of sensors, where the plurality of the sensors are mounted at pre-determined positions in the 3D printer assembly. The sensed parameters of the print material are received by a controller. Further, any variation in consistency of the print material is determined by the controller, by comparing the received parameters of the print material with a pre-determined set of parameters.

In an embodiment of the present disclosure, any variation in the parameters and consistency of the print material is indicated by an indication unit.

In an embodiment of the present disclosure, variation in the parameters and consistency of the print material is indicated by at least one of an audio and visual indicators.

In an embodiment of the present disclosure, an image capturing sensor is provided to assess at least one of compression of the printed layers and the shape of the extruded print material.

In yet another non-limiting embodiment of the present disclosure, a three-dimensional printer assembly is disclosed. The three dimensional printer assembly comprises of a pumping unit adapted to receive print material from one or more sources, where the pumping unit is configured to pump the print material to a nozzle. The nozzle is in communication with the pumping unit by the at least one connecting pipe, where the nozzle prints a plurality of layers of the print material on the work bed. Further, the assembly includes a traversing mechanism configured to selectively regulate movement of the nozzle, where the traversing mechanism is communicatively coupled to the controller, and the controller is configured to selectively control operation of the traversing mechanism. A system for testing the print material printed on the work bed is disclosed and the system includes a plurality of sensors mounted at pre-determined positions on the three-dimensional printer assembly. The plurality of sensors are configured to sense the parameters including at least one of extrudability and workability of the print material. The controller is communicatively coupled with the plurality of sensors, where the controller is configured to receive the parameters of the print material sensed by the plurality of sensors. The controller further compares the received parameters of the print material with a pre-determined set of parameters to determine variation in consistency of the print material.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following description.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

The novel features and characteristic of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:

Figure 1 illustrates a perspective view of a 3D printer system for testing the print material, in accordance with an embodiment of the present disclosure.

Figure 2 illustrates a perspective view of 3D printer system with a progressive cavity pump, in accordance with an embodiment of the present disclosure.

Figures 3a illustrates a perspective view of a multilayered printed structure that is printed from a plurality of batches of print material, in accordance with an embodiment of the present disclosure.

Figure 3b illustrates another perspective view of the multilayered printed structure showing change in the printed structure in view of Figure 3a.

Figure 4 illustrates a flowchart indicating the working of 3D printer system, in accordance with an embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other system for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to its organization, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a system that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such mechanism. In other words, one or more elements in the device or mechanism proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the mechanism.

Embodiments of the disclosure discloses a system for testing print material used for three dimensional printing. Conventionally, consistency of the print material used to vary due to factors like temperature, humidity, quality of binder, evenness in size of the matrix, variation in composition, and the like. These factors may affect characteristics of the print material including, but not limited to, viscosity, adhesiveness, cohesiveness, and the like. Due to this variation in characteristics, the quality of structures printed may be affected. Due to the abovementioned factors, it may be difficult to maintain consistency in characteristics of the print material.

Embodiments of the present disclosure disclose a system for testing print material used for three-dimensional printing. The system includes a three dimensional printer assembly. The assembly includes a pumping unit adapted to receive print material from one or more sources, where the pumping unit is configured to pump the print material to a nozzle. The nozzle is in communication with the pumping unit by the at least one connecting pipe and prints a plurality of layers of the print material on the work bed. Further, a traversing mechanism is configured to selectively regulate movement of the nozzle, where the traversing mechanism is communicatively coupled to the controller, and the controller is configured to selectively control operation of the traversing mechanism.

Embodiments of the disclosure also disclose a system for testing the print material printed on the work bed. The system comprises of a plurality of sensors mounted at pre-determined positions on the three-dimensional printer assembly, where the plurality of sensors are configured to sense the parameters including at least one of extrudability and viscosity of the print material. The controller is communicatively coupled with the plurality of sensors, where the controller is configured to receive the parameters of the print material sensed by the plurality of sensors, compare the received parameters of the print material with a pre-determined set of parameters to determine variation in consistency of the print material.

In the following description of the embodiments of the disclosure, reference is made to the accompanying figures that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

Figure 1 is an exemplary embodiment of the present disclosure, which illustrates a 3D printer system (100) and Figure 2 illustrates a perspective view of 3D printer system (100) with a progressive cavity pump (1). Further, Figure 4 illustrates the working of the 3D printer (100) in a flowchart. A work bed (4) may be employed as a set-up for testing structures produced or developed by the 3D printer (100). The work bed (4) may encompass an analysis unit [not seen in Figures] in the 3D printer (100).

In the figures 1 and 2, test module 3D printer system (100) is illustrated, and it includes a 3D printer assembly (101) which comprises of a pumping unit (1). The pumping unit (1) may be configured to receive a print material, pre-mixed with a defined composition. The print material may be mixed in a mixer unit (not shown in figures), which may be externally associated with the 3D printer (100). The pumping unit (1) may be adapted to contain the print material, which may be employed to produce or print a structure (200). Further, the pumping unit (1) may be configured to discharge a defined quantity of the print material.

In an embodiment, the pumping unit (1) may comprise of a primer unit (1a) and a pump (1b). The primer unit (1a) may be fluidly connected to a pump (1b), by means of connecting pipes (10) including, but not limited to, hoses, channels, tubes, and the like. The pump (1b) may further discharge a defined quantity of the print material contained in the primer unit (1a).

Further, the print material discharged from the pumping unit (1), may be configured to be dispensed for printing through a nozzle (3). The print material pumped by the pumping unit (1) to the nozzle (3) may be controlled by a controller (11). The nozzle (3) may be adapted to either continuously or discretely dispense the print material for printing the structure (200) on a work bed (4) of the 3D printer (100). The nozzle (3), as per design requirement, may be configured to restrain dispensing of the print material in order to continue printing at a different position. At that instance, the nozzle (3) may be moved to the defined position for commencing dispense of the print material on the work bed (4). Further, the nozzle (3) may be coupled to a traversing mechanism, where the traversing mechanism may be selectively operable, for moving the nozzle (3) over the work bed (4). The nozzle (3) may be defined with a predetermined profile, where the nozzle (3) may be adapted to dispense the print material in a defined pattern, upon selective displacement by the traversing mechanism.
In an embodiment, the 3D printer system (100) prints material with aggregate mixes of different sizes. The 3D printer system (100) may print material with small aggregate mix designs containing only sand or fine particulate material. The 3D printer system (100) may also print material of medium or large aggregate mix designs containing gravel and crushed stones.

In an embodiment, the traversing mechanism may include a locomotion unit (2) for displacing the nozzle (3) to different positions on the work bed (4). The traversing mechanism may be a rack and pinon arrangement or a first and a second set of rails (5 and 6). The mechanisms used for displacing the nozzle (3) is however not be limited to the above mentioned mechanisms. Instead, any mechanisms known in the art may be employed for enabling the movement of the nozzle (3) along the work bed (4). Further, the movement of the nozzle (3) herein is enabled with the aid of the first and the second set of rails (5 and 6). The first set of rails (5) may be disposed on either side of the work bed (4), about a longitudinal direction. One end of the pair of support frames (8) may be slidably connected to each rail of the first set of rails (5), to impart movement of the nozzle (3) about the longitudinal direction [that is, about X-axis] of the work bed (4). The second set of rails (6) may be disposed across the first set of rails (5) and may be connected at other end of each of the pair of support frames (8). This way, the nozzle (3) may impart movement about a lateral direction [that is, about Y-axis] of the work bed (4). Further, between each of the second set of rails (6), the linear guide member (7) is disposed. The linear guide member (7) may be adapted to accommodate the nozzle (3), where the linear guide member (7) may be configured to displace the nozzle (3) in a transverse direction to the work bed (4) [that is, along Z-axis], based on the requirement. In addition, auxiliary guide members (9) may be coupled to the work bed (4), for suitable displacement, during printing or post-printing process. Also, each of the first set of rails (5), the second set of rails (6), the linear guide member (7) and the auxiliary guide members (9) may include a plurality of actuators, which may be regulated either manually or automatically to control movement of the nozzle (3) on the work bed (4). With reference to the Figure 4, a stereolithography (STL) CAD model of the required constructional shape may be initially uploaded onto a controller (11). Further, the controller (11) may convert the STL model into readable references Further, the traversing mechanism of the 3D printer (100) may operate in accordance with the referenced and consequently print a structure of required constructional configuration.

Upon operation of the plurality of actuators, the nozzle (3) may be displaceable about the lateral direction, the longitudinal direction, and the transverse direction with respect to the work bed (4). Each of the plurality of actuators may be operable vis-à-vis the defined pattern set by a user [or an operator] in a controller (11) [not seen in Figures]. The controller (11) may be configured to selectively actuate one or more actuators of the plurality of actuators [not shown], in order to move the nozzle (3) about the work bed (4) such that, the print material dispensed through the nozzle (3) may be refrained from randomly spreading on the work bed (4). This way, the nozzle (3) may be traversed on the work bed (4) in the defined pattern for printing the structure (200). Also, the controller (11) may selectively actuate each of the plurality of actuators associated with the linear guide member (7), for adjusting distance between the nozzle (3) and at least one of the work bed (4) and a layer of the printed structure (200). Based on the adjustment, by the controller (11), the nozzle (3) may dispense the print material to form a stratified or multilayered structure (200).

In an embodiment, the controller (11) may be configured to individually operate each of the plurality of actuators for independently moving the nozzle (3) over the work bed (4), along the first set of rails (5), the second set of rails (6) and the linear guide member (7). Due to this independent movement of the nozzle (3), the print material may be successively dispensed in the defined pattern, to form stratified or multilayered structure (200), as can be seen in Figures 2a and 2b. Also, a specified time interval and movement rate of the nozzle (3) may be pre-set by the controller (11), in order to allow the printed print material to attain a predefined rigidness and dryness. Upon attaining the predefined rigidness and dryness, the printed print material may be suitable for stratification.

The print material may be formed by blending a matrix and a binder in a specific composition rate. The matrix may be at least one of crushed stones, sand, and the like. The binder may be cement including, but not limited to, Portland cement. Further, water, at defined quantity, may be added to the matrix and the binder to produce the print material in the form of a mush. The blending of the matrix and the print material in the mixture unit may be performed either manually or by a mechanism associated with the mixing unit. In this way, the print material may be produced in batches over a period of time, for use in the 3D printer (100) to print the structures.

In an embodiment, composition, or proportion of the matrix in respect of the binder may be pre-calculated and fed to the controller (11) associated with the 3D printer (100). Also, for each batch of the print material, the composition or proportion may be noted and fed to the controller (11). Further, a defined quantity of the print material may be employed for testing and analysis, prior dispensing for printing the structure (200). The analysis may be performed in order to determine consistency of the print material produced in each batch.

The 3D printer system (100) may incorporate a plurality of sensors, to sense operational aspects of each component in the 3D printer system (100). The plurality of sensors may be including, but may not be limited to, a proximity sensor, a pressure sensor, an image capturing unit, a flow rate sensor, and the like. Further, each of the plurality of sensors may be communicatively coupled to the controller (11), in order to transmit an input signal, in real-time, pertaining to various operational aspects of the 3D printer system (100).

In an embodiment, the pressure sensor may be positioned at an outlet of the pumping unit (1), in order to determine pressure with which the print material may be pumped from the pumping unit (1). The controller (11) may be configured to receive an input signal from the pressure sensor and, may compare the input signal with a defined value of pre-set pressure for the pumping unit (1). Deviation in values from the pressure sensor with that of the pre-set pressure of the pumping unit (1) may be determined and analyzed by the controller (11). The pressure sensor of the 3D printer system (100) may assist the controller (11) in determining the extrudability of the print material. Extrudability may be defined as the ability of the print material to be extruded through the nozzle (3) of the 3D printer system (100) with minimal energy needed. For instance if the pressure sensor detects that an excessive pressure is being applied by the piston inside the pumping unit (1) to force the print material through the nozzle (3), the controller (11) may accordingly indicate to the operator that the viscosity of the print material is very high. Based on the readings from the controller (11), the operator may choose to vary the composition of the print material to required levels before using the print material on a large scale printer. Further, if the pressure recorded from the pressure sensor housed inside the pumping unit (1) is very low, the controller (11) may indicate to the operator that the viscosity of the print material is very low. Further, under circumstances where the viscosity of the print material is very low, the ability of the deposited print material to retain its dimensions reduces drastically. Consequently, a drop in pressure recorded from the pressure sensor may be indicative of low viscosity of the print material. Based on the detected pressure, the controller (11) may compare the pressure values with pre-determined values and accordingly indicate to the operator any variation is the pressure. Further, depending on the indicated pressure from the controller (11), the above-mentioned factors such as extrudability and viscosity of the print material may be determined. The controller (11) may suitably indicate the above parameters and consequently enable the operator to vary the composition of the print material to required compositions. Further, the flow rate sensor, such as, but not limited to, a venturi meter, may be employed proximal to an outlet port [not seen in figures] of the nozzle (3), to determine rate at which the print material is being dispensed for printing on the work bed (4). It may be noted that, on the contrary to position the flow rate sensor in the nozzle (3), the flow rate sensor may also be positioned at an outlet of the pumping unit (1), to sense the rate of flow of the print material. The flow rate sensor may transmit the input signal to the controller (11), which may compare with the pre-calculated characteristics of the print material, based on the composition of the matrix and the binder. The flow rate sensor may also indicate the viscosity. A high value of flow rate of the print material is indicative of low viscosity. For instance, when the flow rate of the print material is very high, the ability of the print material to be deposited on another layer of print material and retain the dimensions on that layer is very low. High flow rate indicates that the print material may flow away without retaining its dimensions. The flow rate sensor detects the flow rate of the print material and communicated to the controller (11). The controller (11) compares the flow rate value with the pre-determined flow rate and accordingly indicates to the operator any deviation in flow rate of the print material. Based on the indicated flow rate value, the operator may vary the composition of the print material to maintain the required consistency.

In addition, the proximity sensor and the image capturing unit may be positioned proximal to the nozzle (3), where the proximity sensor and the image capturing unit may be configured to sense the nature of printing of the print material through the nozzle (3). For example, the proximity sensor may be configured to determine steady movement of the nozzle (3) relative to surface of the work bed (4). Further, a flatness gauge (either optical or mechanical) may be coupled to the nozzle (3) to determine flatness of the printed print material on the work bed (4) or on another printed surface, as best seen in Figure 3a. The image capturing sensor may be configured to determine the deviation in the printed print material either laterally or longitudinally, as best seen in Figure 3b. For instance, two consecutive layers of print material may be printed on to the work bed (4) and the height of the two consecutively printed layers is taken as input, by the controller (11). This height may be compared with the desired height already input in the controller (11). The difference between the Set-Point and the measured height provides information on the effect of compression between the bottom and the top layer. The compression of the consecutively printed layers may be determined by the proximity sensor. For e.g. the nozzle may lay the print material onto the work bed (4) from a pre-set distance and the thickness of each layer of the printed material may be 10 mm. Thus, the total thickness of the two consecutive layers of printed material is 20 mm. Once consecutive layers of print material are printed onto the work bed (4), the total height of the consecutive printed layers may be suitably measured using the proximity sensor in the nozzle (3). If the total height of the printed layers is recorded to be less than 20 mm, it becomes evident that the printed layers have compressed due to self-weight. Compression beyond a certain set point is again an indication of poor buildability of the print material. Excessive compression again indicates that the print material has poor buildability. The measured height of the consecutive printed layers may be recorded by the controller (11) and may be indicated to the operator if the measured height is below a set point. Thus, the proximity sensor may assist in conducting a layer compression test of the print material. Further, the image capturing sensor may also be configured to assess the compression of the bottom layer and the image capturing sensor may also assess the shape of the extruded profile. For instance, if any anomalies are detected in the shape of the extruded print material, the controller (11) which is commutatively coupled with the image capturing sensor may suitably indicate the operator.

Further, the controller (11) may be configured to determine the deviation in printability of the print material in view of the factors including, but not limited to, flow rate of the print material in the pumping unit (1) and through the nozzle (3), compression of the printed print material due to self-weight, and other similar factors. Based on these factors, the controller (11) may be configured to alert the user or operator to modify composition of the print material for printing.

The size of the above-mentioned 3D printer is significantly smaller than the size of standard 3D printers. The compact arrangement of the 3D printer enables the above-mentioned 3D printer to be solely used as a testing apparatus for testing the various parameters of the print material. The small scale arrangement of 3D printer ensures that a minimal amount of print material is used for achieving the required quality of print material before being used for large sale 3D printer.

In an embodiment, the first set of rails (5), the second set of rails (6), the linear guide member (7) and the auxiliary guide members (9) may be at least one of a ball screw, a lead screw, a parallel bar arrangement, and the like.

In an embodiment, the 3D printer system (100) may be a miniature version of a real scale 3D printer system (100). Likewise, the structure (200) formed in the work bed (4) may be a scaled-down version of the structure (200) formed by the real scale 3D printer system (100) for testing purposes. Consequently, the print material may be tested in a quick, and easy manner before being used on a large sale printer.

In an embodiment, the plurality of actuators may be including, but not limited to, DC motors, AC motors, stepper motors, servo motors, hydraulic and pneumatic actuators, and the like. Each of the plurality of actuators may be operated by the controller (11), for traversing the nozzle (3) about the work bed (4).

EQUIVALENTS

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.
Referral numerals:

Particulars Numerical
Pumping unit 1
Primer unit 1a
Pump 1b
Nozzle 3
Work bed 4
First set of rails 5
Second set of rails 6
Linear guide member 7
Support frame 8
Auxiliary guide members 9
Connecting pipes 10
Controller (11) 11
3D printer 100
Structure 200
,CLAIMS:We claim:

1. A system (100) for testing print material used for three-dimensional printing, the system comprising:
a work bed (4);
a three-dimensional printer assembly (101), configured to print a plurality of layers of the print material to be tested on the work bed (4);
a plurality of sensors mounted at pre-determined positions on the three-dimensional printer assembly (101), wherein the plurality of sensors are configured to sense parameters including extrudability and viscosity of the print material;
a controller (11) communicatively coupled with the plurality of sensors, wherein the controller (11) is configured to:
receive the parameters of the print material sensed by the plurality of sensors; and
compare the received parameters of the print material with a pre-determined set of parameters to determine variation in consistency of the print material.

2. The system as claimed in claim 1, wherein the plurality of sensors include a pressure sensor positioned at an outlet of a pumping unit (2), the pressure sensor is configured to detect pressure with which the print material is pumped from a pumping unit (1), wherein the pressure detected is indicative of extrudability and viscosity of the print material.

3. The system as claimed in claim 2, wherein the pumping unit (1) comprises of a primer unit (1a) and a pump (1b) for pumping the print material.

4. The system as claimed in claim 1, wherein the plurality of sensors include a flow rate sensor positioned proximal to an outlet port of the nozzle (3), the flow rate sensor is configured to detect flow rate of the print material, wherein the flow rate detected is indicative of viscosity of the print material.

5. The system as claimed in claim 1, wherein the plurality of sensors include a proximity sensor positioned proximal to the nozzle (3), the proximity sensor is configured to determine the compression of at least one layer of print material extruded on to the work bed (4).

6. The system as claimed in claim 1, comprises an indication unit communicatively coupled with the controller (11), wherein the controller (11) is configured to indicate variation in the consistency of the print material through the indication unit, based on the comparison.

7. The system as claimed in claim 6, wherein the indication unit is at least one of an audio and visual indicator.

8. The system as claimed in claim 1, wherein the, the three-dimensional printer assembly (101) comprises:
a pumping unit (2) adapted to receive the print material and pump the print material;
a nozzle (3) connected to the pumping unit (2), wherein the nozzle (3) prints a plurality of layers of the print material on the work bed (4);
a traversing mechanism configured to selectively regulate movement of the nozzle (3), wherein the traversing mechanism is communicatively coupled to the controller (11), and the controller (11) is configured to selectively control operation of the traversing mechanism.

9. The system as claimed in claim 8, wherein the traversing mechanism includes:
a locomotion unit (2) provided on either sides of the work bed (4), wherein the locomotion unit (2) comprises of a first set of rails (5) and a second set of rails (6);
a support frame (8) slidably connected to the first set of rails (5), wherein the support frame (8) is coupled to an actuator to impart movement of the nozzle (3) in a longitudinal direction;
a second set of rails (6) positioned perpendicular to the first set of rails (5) configured to accommodate a linear guide member (7) holding the nozzle (3), wherein the linear guide member (7) is coupled to at least one actuator for imparting movement of the nozzle (3) in at least one of lateral and transverse directions.

10. The system as claimed in claim 9, wherein the locomotion unit (2) is at least one of a rack and pinon arrangement and set of rails (5) provided on either sides of the work bed (4).

11. The system as claimed in claim 9, wherein the movement of the linear guide member (7) along the second set of rails (6) facilitates the movement of the nozzle (3) along the lateral direction.

12. The system as claimed in claim 1, comprising an image capturing sensor to assess at least one of compression of the printed layers and the shape of the extruded print material.

13. A method for testing parameters of print material, the method comprising:
printing, by a three-dimensional printer assembly (101), a plurality of layers of print material on a work bed (4);
sensing, by a plurality of sensors, the parameters including at least one of extrudability and viscosity of the print material, wherein the plurality of the sensors are mounted at pre-determined positions in the 3D printer assembly (101);
receiving, by a controller (11), the parameters of the print material sensed by the plurality of sensors;
determining by the controller (11), any variation in consistency of the print material by comparing the received parameters of the print material with a pre-determined set of parameters.

14. The method as claimed in claim 13, wherein any variation in the parameters and consistency of the print material is indicated by an indication unit, configured to suitably indicate.

15. The method as claimed in claim 13, wherein variation in the parameters and consistency of the print material is indicated by at least one of an audio and visual indicators.

16. A three-dimensional printing test module comprising:
a three dimensional printer assembly (101), comprising:
a pumping unit (1) adapted to receive print material from one or more sources, wherein the pumping unit (2) is configured to pump the print material to a nozzle (3);
wherein, the nozzle (3) in communication with the pumping unit (2) by the at least one connecting pipe (10), and the nozzle (3) prints a plurality of layers of the print material on the work bed (4);
a traversing mechanism configured to selectively regulate movement of the nozzle (3), wherein the traversing is communicatively coupled to the controller (11), and the controller (11) is configured to selectively control operation of the traversing mechanism;
a system for testing the print material printed on the work bed (4), the system comprising:
a plurality of sensors mounted at pre-determined positions on the three-dimensional printer assembly (101), wherein the plurality of sensors are configured to sense the parameters including at least one of extrudability and viscosity of the print material;
the controller (11) communicatively coupled with the plurality of sensors, wherein the controller (11) is configured to:
receive the parameters of the print material sensed by the plurality of sensors; and
compare the received parameters of the print material with a pre-determined set of parameters to determine variation in consistency of the print material.

Dated 30th day of July 2019

GOPINATH A S
IN/PA 1852
OF K&S PARTNERS
AGENT FOR THE APPLICANT