Additive manufacturing style printers, such as three-dimensional (3D) printers, may utilize powdered building materials to print the manufactured or printed object. The powdered building material may be circulated through the printer during the printing operation and can sometimes cause clogs or blockages which should be cleared to enable efficient and proper operations with the printer.
Various examples will be described below referring to the following figures:
In the figures, certain features and components disclosed herein may be shown exaggerated in scale or in somewhat schematic form, and some details of certain elements may not be shown in the interest of clarity and conciseness. In some of the figures, in order to improve clarity and conciseness, a component or an aspect of a component may be omitted.
In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to be broad enough to encompass both indirect and direct connections. Thus, if a first device couples to a second device, that connection may be through a direct connection or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the given axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis.
As used herein, including in the claims, the word “or” is used in an inclusive manner. For example, “A or B” means any of the following: “A” alone, “B” alone, or both “A” and “B.” In addition, when used herein, including the claims, the word “generally” or “substantially” means within a range of plus or minus 20% of the stated value. As used herein, the terms “downstream” and “upstream” are used to refer to the arrangement of components and features within a printer with respect to the “flow” of print media through the printer during a printing operation. Thus, if a first component of a printer receives print media after it is output from a second component of the printer during a printing operation, then the first component may be said to be “downstream” of the second component and the second component may be said to be “upstream” of the first component.
As previously described, the powdered building material used within an additive manufacturing printer (e.g., a 3D printer) may cause clogs or other flow restrictions as it is circulated about the printer. These flow stoppages can hinder printing operations, and may even cause damage to components of the printer (e.g., due to pressure increases). Accordingly, examples disclosed herein include fluid flow devices for use within an additive manufacturing printer that prevent (or reduce) the occurrence of clogs, blockages, or restrictions and promote a relatively constant flow of powdered building materials within the printer during operations. As a result, use of the disclosed fluid flow devices may improve the reliability and efficiency of such 3D printers.
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Build surface 12 is a substantially flat surface that supports a three-dimensional (3D) printed object. Surface 12 is movably disposed between a plurality of walls 14. During operations, surface 12 may be disposed vertically below a topmost end of the walls 14 such that a chamber or vessel 16 is defined by the walls 14 and surface 12 that is open at a vertical upper end.
During a printing operation, powdered building material is flowed, dumped, poured or otherwise provided into vessel 16. The powdered building material (which may be more simply referred to herein as a “powder”) may comprise any suitable powdered material for use within a 3D printing operation, such as, for example, powders comprising plastics, metals, ceramics, or combinations thereof. Thereafter, a roller or other skimming member (not shown) is moved laterally over surface 12 (and vertically spaced above surface 12 by a predetermined amount) to skim excess powder into chambers 50, and to ensure that the upper surface of the powder is substantially flat or planar in the lateral direction. In some implementations, the powder is first deposited on a separate platform or surface (not shown) that is adjacent to the build surface 12, and thereafter, the powder is spread (e.g., via a roller or other suitable device) from this adjacent platform onto the build surface 12.
After the surface of the powder is flattened (or simultaneously with flattening the surface of the powder), a printing mechanism (e.g., a print head, roller, or combination thereof) deposits a layer of printing agent (which may comprise a printing liquid such as ink in some implementations) onto the powder within vessel 16 in a desired pattern, such as, for example, the outline of a two-dimensional section of the three-dimensional object to be printed. In this example, the printing agent deposited onto the powder is a darker color than the surrounding powder material.
After the printing agent has been deposited on the powder, energy (e.g., such as light, heat, radiation, or some combination thereof) is directed at the powder within vessel 16. Because of the relatively darker color of the printing agent that was previously printed onto the powder, a relatively higher amount of energy is absorbed by the printing agent (and thus the powder bearing the printing agent thereon) so that the powder bearing the printing agent melts and fuses. In other implementations, the printing agent may or may not be darker than the surrounding powder material, and may also include other material properties (e.g., such as chemical composition or structure) that allow the printing agent to absorb a relatively higher amount of energy to therefore facilitate the melting and fusing operations previously described above. As a result, applying energy to the printed printing agent produces a fused layer of material that matches, or closely matches, the outline of the two-dimensional section that was previously printed on the powder. Following this fusing operation, the surface 12 is lowered a predetermined amount relative to the walls 14 and a fresh layer of powder is deposited on top of the previously fused powder layer within vessel 16. Thereafter, the above described operations are repeated to form another 2D layer of the 3D object. As each layer of powder fuses to itself in the manner described above, the powder forming each 2D layer also fuses or otherwise binds to the immediately adjacent 2D layer below it. Accordingly, through this process, a 3D object is built or printed layer by layer within vessel 16.
As can be appreciated from the above described printing operation, a large amount of excess powder can be expelled from vessel 16 into adjacent chambers 50 with the printing of each successive 2D layer. This excess powder is circulated out of chambers 50 and back to a storage reservoir 30, such that the powder can be either disposed of or reused. In particular, air (or some other fluid) is drawn into an intake 25 (or plurality of intakes) through a plurality of lines or conduits 20 by vacuum source 34, that is coupled to reservoir 30 via a conduit 32 and which may comprise any suitable pump(s), compressor(s), or combination thereof. The air flows through fluid flow devices 100 which are in communication with chambers 50 and entrains powder that falls into fluid flow devices 100 from chambers 50. As a result, the powder is carried from fluid flow devices 100 by the air, through lines 22, and into reservoir 30. Lines or conduits 20, 22, 32 may comprise any suitable conduit capable of delivering a flow of fluid therethrough, such as, for example, pipes, hoses, channels, etc.
As will be described in more detail below, fluid flow devices 100 are arranged to provide a relatively constant flow of powder into lines 22 and to reduce and prevent blockages or other flow restrictions therein. As a result, the pressure within lines 20, 22, 32 may remain relatively constant and the pressure increases often associated with flow restrictions are reduced or eliminated. Further details regarding the fluid flow devices 100 are described herein with general reference to
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A plate 150 is mounted within central section 112 of fluid flow passage 108 that is axially spaced from and disposed between walls 112a, 112b along axis 125. Plate 150 includes a first or upper side 151, a second or lower side 153 axially opposite upper side 151 along axis 125, and a radially outermost perimeter edge 152 that extends axially between sides 151, 153 along axis 125. In this example, plate 150 includes a circular radial cross-section with respect to axis 125, so that each side 151, 153 is circular in shape. However, it should be appreciated that plate 150 may comprise any suitable shape or size, in other implementations, such as, for example, rectangular, square, oval, triangular, etc.
In this example, plate 150 is axially spaced from top wall 112a and port 120 and is axially spaced from bottom wall 112b along axis 125. As a result, upper side 151 is axially spaced from port 120 and top wall 112a and lower side 153 is axially spaced from bottom wall 112b with respect to axis 125. In this example, plate 150 is axially equidistant from top wall 112a (and thus port 120) and bottom wall 112b; however, in other examples plate 150 may be disposed axially closer to top wall 112a (and port 120) than bottom wall 112b, or may be disposed axially closer to bottom wall 112b than top wall 112a (and port 120). Therefore, plate 150 divides central section 112 of fluid flow passage 108 into a first or upper passage 113 axially between upper side 151 of plate 150 and port 120 (and top wall 112a) and a second or lower passage 115 axially between lower side 153 of plate 150 and bottom wall 112b.
In addition, in this example, plate 150 is coaxially aligned with port 120 along axis 125 and has a larger radial cross-sectional area than the port 120 with respect to axis 125. In addition, radially outer perimeter edge 152 of plate 150 is disposed radially farther from axis 125 than perimeter walls 122 of port 120 along the entire perimeters of port 120 and plate 150 (i.e., outer perimeter edge 152 of plate 150 is disposed radially outside of perimeter walls 122 of port 120 about the entire perimeters of plate 150 and port 120).
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During a printing operation, fluid (e.g., air) is flowed through fluid flow passage 108, between the inlet 104 and outlet 106 to transport powder 80 from upper side 151 of plate 150 to outlet 106. In particular, an air flow is induced through fluid flow device 100 via the vacuum source 34 as previously described such that powder 80 exiting outlet 106 may be provided to reservoir 30 via lines 22. Because powder 80 is retained within a portion of upper passage 113 as previously described, the air flowing through fluid flow device 100 is allowed to flow freely through the lower passage 115 and radially (with respect to axis 125) between plate 150 and side walls 112c, 112d. Thus, a minimum flow of air is maintained through fluid flow device 100 during printing operations, regardless of whether powder 80 is disposed within upper passage 113 via port 120. In addition, during these operations, the air flowing through fluid flow device 100 may also flow within upper passage 113 around the pile of powder 80 disposed on upper side 151 of plate 150. As the fluid flows past the powder 80 within upper passage 113, particles of the powder are entrained in the flowing fluid and are carried or swept from fluid flow passage 108 via outlet 106. Thereafter, the powder 80 is carried to reservoir 30 (see
Accordingly, because plate 150 ensures a minimum flow rate through fluid flow passage 108, when powder 80 is provided from chamber 50 via port 120, fluid flow device 100 provides a relatively constant and consistent flow rate of powder 80 to reservoir 30. A constant (or relatively constant) flow rate of powder 80 between fluid flow device 100 and reservoir 30 is desirable since it avoids (or reduces) the occurrence of slug flow and the pressure spikes or increases which are associated with such a flow scheme. These pressure increases can cause wear and failure (e.g., fatigue, overpressure, etc.) for components of the printer system (e.g., vacuum source 34, lines 20, 22, 32, etc.). As a result, the use of the example fluid flow device 100 disclosed herein may increase the useable life of components within printing system 10. In addition, by avoiding slug flow and flow restrictions (the associated pressure variations associated therewith), the load on the vacuum source 34 remains relatively constant so that the sizing and performance of vacuum may be optimized for increased efficiency and cost-effectiveness.
Further, without being limited to this or any other theory, flow rate of powder 80 from fluid flow device 100 may be a function of the exposed surface area of the powder 80 to the flowing fluid, and this exposed surface area is a direct result of the axial spacing between the plate 150 and port 120 along axis 125 and of the characteristics of the powder 80. Therefore, adjustments in the flow rate of powder 80 from fluid flow device 100 may be achieved by, for example, adjusting the axial spacing of plate 150 from port 120 within fluid flow passage 108.
Examples disclosed herein have provided fluid flow devices for use within an additive manufacturing printer (e.g., fluid flow device 100) that prevent (or reduce) the occurrence of clogs, blockages, or restrictions in the flow of powdered building materials within the printer. In addition, the fluid flow devices disclosed herein promote a relatively constant flow rate of powdered printing material through the printer. Accordingly, through use of the fluid flow devices disclosed herein, the reliability and efficiency of an additive manufacturing style printer (e.g., printing system 10) may be increased.
While examples of the fluid flow devices disclosed herein (e.g., fluid flow device 100) have been used to flow excess powder provided to chambers that are adjacent a build surface (e.g., surface 12) within an additive manufacturing style printer, it should be appreciated that the fluid flow devices may be utilized in other portions of printing system 10 in other implementations. For example, in some implementations, the fluid flow devices may be used to flow or deliver fluid falling through holes disposed in the printer build chamber (e.g., through holes disposed in surface 12) to a reservoir (e.g., reservoir 30) for later reuse, or disposal.
The above discussion is meant to be illustrative of the principles and various examples of the present disclosure. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
Filing Document | Filing Date | Country | Kind |
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PCT/US2018/042680 | 7/18/2018 | WO | 00 |