Some tri-dimensional (3D) printing apparatus comprise a build material container, which may be loaded with an amount of build material, such as build powder. To generate a 3D object, build material from the build material container may be spread in successive layers on a build platform, where each layer may be selectively solidified to generate the 3D object layer by layer.
Some non-limiting examples of the present disclosure will be described in the following with reference to the appended drawings, in which:
Some 3D printing systems use build material that have a powdered, or granular, form. According to one example a suitable build material may be a powdered semi-crystalline thermoplastic material. One suitable material may be Nylon 12, which is available, for example, from Sigma-Aldrich Co. LLC. Another suitable material may be PA 2200 which is available from Electro Optical Systems EOS GmbH.
In other examples other suitable build materials may be used. Such materials may include, for example, powdered metal materials, powdered plastics materials, powdered composite materials, powdered ceramic materials, powdered glass materials, powdered resin material, powdered polymer materials, and the like.
In some implementations other suitable build materials may be used, such as for example fluid or viscous build materials.
A build material container for 3D printing apparatus may be provided on a trolley or building unit, which may also comprise the build platform, for example at the top of the build material container. The build material container may be loaded with a build material, such as a build powder, and the trolley or building unit may then be docked in a 3D printing apparatus for manufacturing 3D objects.
However, in other implementations, the build material container may be incorporated in the 3D printing apparatus as a part that is not intended to be separated from the apparatus.
In some implementations, a movable build platform on which the 3D objects are generated in successive layers may be placed above the build material in the build material container, and may be lowered after each layer, such that the space or volume available for the build material in the build material container may be variable.
During different stages of operation of the 3D printing apparatus it may be convenient to measure the amount of build material in the build material container.
For example, manufactured 3D objects may have better quality if there are no interruptions during the process. In order to estimate if an object may be manufactured without interruptions, it may be useful to know the amount of build material remaining in the build material container before starting the generation of the object. If the remaining amount is not sufficient, a warning to refill the build material container may be issued.
The measure of the amount of build material in the build material container has to be made in an environment with dust, noise and the risk of electrostatic discharges, and taking into account that build material distribution inside the container may be irregular: build material may for example form irregular shapes and cavities, the surface of the build material may not be even and may not be settled. Furthermore, some build material may become attached to the walls or to other surfaces of the build material container.
Furthermore, the build material container may be mounted on a movable trolley or building unit, and/or the space for the build material may be variable due to the movement of the build platform, as discussed above.
At 510 the belt element, and the body attached to the belt element, may be driven towards a surface of the build material, while measuring at 520 the advance and the speed of the belt element.
The speed of the belt element may be monitored at 530 to detect a speed reduction: in case of a positive detection, it may be determined at 540 that the body has contacted the surface of the build material, since the build material at least hinders the advance of the body.
The position of the surface of the build material may be determined at 550, based at least on the advance of the belt element that has been measured.
The amount of build material in the build material container may be derived from the determined position of the surface of the build material and the dimensions of the build material container.
With reference to
The body 140 may move up and down inside the container driven by a movement of the belt element 110. In some implementations the shafts 120 and 130 may be pulleys or the like, and the belt element 110 may be an endless belt element, mounted in close loop (not shown in
The system 100 may comprise a motor 150, to advance the belt element 110 and the body 140 towards a surface 220 of the build material 210 that is inside the build material container 200, and a sensor 160 to detect the advance of the belt element 110.
In some implementations the motor may cause the advance of the belt element 110 by driving in rotation one of the shafts, for example shaft 120 as schematically shown in
In some implementations the sensor 160 may comprise an encoder, and it may detect the advance of the belt element 110 by detecting the rotation of the motor 150, for example of the motor axis (not shown). However, other solutions are also possible: for example, in some implementations an encoder or other kind of sensor 160 may detect the advance of the belt element 100 directly by readings of the belt element 110, which in this case may be provided with visible marks or other elements detectable by the sensor 160.
In implementations as shown in
When the speed of the belt element 110 decreases, the controller 170 may determine that the body 140 has contacted the surface 220 of the build material 210, since the contact with the build material 210 hinders or prevents the advance of the body 140 and of the belt element 110 to which the body 140 is attached.
The controller 170 may also control the operation of the motor 150.
Implementations of a method for measuring the amount of build material in a build material container of a 3D printer, such as disclosed above, may be carried out with a system such as illustrated by
Implementations of the method and system disclosed herein allow providing robust and reliable measures of the amount of build material present in a build material container, even in the difficult conditions that may be found inside the container itself, which is an environment subject for example to large amounts of dust, to movements and vibrations, and to electrostatic charges.
The system relies on the tension of the belt element, and on the determination that the body has reached the build material surface when the belt element reduces its speed. The body may be advanced together with the belt element until it safely contacts the surface of the build material, and the risk of errors in the readings due to the body being deflected or blocked by irregularly accumulated build material, or by friction, may be reduced by virtue of the belt element being mounted under tension between at least two shafts. A relatively light weight body may be employed, since the system is not based on gravity for the advance of the body. For the same reason, the weight of the belt element is not relevant for the advance of the body, and therefore the belt element may be designed as convenient to avoid friction issues, to be placed in a suitable position in the container, etc.
Implementations of the system and method may operate with different build materials, container sizes or geometry, and build material distributions within the build material container.
The mounting of the belt element tensioned between at least two shafts may allow flattening or stabilizing the build material surface before a measure is taken, for example by exerting a force on the surface, as disclosed later on, so accuracy in the measures may be increased.
As shown in
The motor 150 may be mounted inside the container 200 to drive pulley 120, and the sensor 160 may be an encoder integrated to detect the rotation of the motor axis. The controller 170 may receive the signals from the sensor 160, in order to determine when the body 140 reaches the surface 220, and the position of the surface 220, as described above. The controller 170 and may also control the operation of the motor 150.
In some implementations, in a system such as shown in
In implementations of a system as disclosed herein, the body 140 may comprise a conical portion 142. For example, the outer surface of the body 140 may be substantially conical, as shown by way of example in
A conical portion 142 reduces the risk that the body 140 may become buried and trapped in the build material, for example if build material is supplied to the container and falls on the body 140, because the conical portion 142 facilitates the extraction of the body upwards from the build material. Other outer shapes of the body 140 are possible, for example other shapes that are relatively narrow at the top and widen downwards (with the body in the use position), such as pyramidal shapes or truncated cone or pyramid shapes.
The recessed space formed between the flat base 144 and the rim 145 in the lower part of the body 140 of
In some implementations of the system, the body 140 may comprise a grid 146, intended to contact the build material and allow the body to settle in a stable and reliable way on the surface of the build material.
However, the grid may be constructed in other suitable ways, such as for example with bars of different geometry and arranged in different patterns, or perforated plates, or meshes or the like, or a combination thereof. It may have any suitable peripheral shape and any suitable dimension. In some implementations the grid 146 may be attached to a conical portion 142 to form a base portion or sole portion of the body 140, as shown in
The belt element 110 may be, in some implementations, an endless belt element, mounted in closed loop between two or more shafts, as shown by way of example in
In some implementations a belt element 110 as used herein may be for example a flat belt, V belt, multi-groove belt, or other, which may be for example of an elastomeric material, with or without reinforcements. However, in some implementations the belt element may also have other suitable shapes and comprise other suitable materials. For example it may have the shape of a cord or cable. The belt element may be for example a metallic or polymeric cable of round section, a multifilament cable, or other.
The shafts 120, 130, and/or any other shafts around which the belt element 110 is to be mounted, may have shapes that are suitable for the shape and material of the belt element 110 selected for each implementation.
In order to improve the reliability of the measures of the advance of the belt element, according to some implementations the belt element 110 and at least one of the shafts 120, 130, and/or others if present, may comprise an anti-slippage system which may prevent or reduce slippage between the belt element and the shafts.
Examples of anti-slippage systems that may be employed in some implementations may comprise coatings provided e.g. on a shaft to increase the friction with the belt element, for example in the case of a metallic belt element, or they may comprise winding the belt element around the shafts by more than one turn.
Slippage may also be reduced or avoided by providing a toothed belt element and at least one matching toothed shaft, or by employing a chain as a belt element and sprockets by way of shafts, in order to provide a positive drive between the belt element and the shaft.
Implementations of systems for measuring an amount of build material as disclosed above may be employed in a build material container in a 3D printer, in order to measure and monitor the amount of build material present in the container during the 3D printer operation and/or between jobs. In some implementations, this may allow issuing a warning or preventing a new job from being started if the measured amount of build material is low: for example, if it is below a predetermined threshold, or if it is determined that it is not sufficient to complete the following job.
In some implementations, the system for measuring the amount of build material comprises a belt element 110, mounted tensioned, as shown by arrow T, between at least two shafts 120 and 130, and extending through the build material space 205, to which a body 140 is attached so as to be displaced together with the belt element 110. The system 100 may comprise, as shown, a motor 150 to drive the belt element, a sensor 160 to detect the advance of the belt element 110, for example by readings of the rotation of the motor 150, and a controller 170.
The controller 170 may control the operation of the motor 150 to drive the belt element 110 and the body 140 towards the build material surface 220, and it may receive data of the advance of the belt element 110 from the sensor 160. With this data the controller 170 may measure or monitor the advance and the speed of the belt element 110 during the movement.
The controller 170 may determine that when the speed of the belt element 110 decreases, the body 140 has contacted a surface 220 of the build material 210.
A decrease in speed of the belt element may be detected by the controller 170 by detecting from the readings of the sensor 160 that the speed of an output shaft (not shown) of the motor 150 is below a predetermined threshold, which may be set for example by performing a calibration of the system. In some implementations, the controller 170 may determine that the body 140 has contacted the surface 220 of the build material 210 when the readings of the sensor 160 show that the speed of the output shaft of the motor 150 is zero.
The controller 170 may then determine the position of the surface 220 of the build material 210, based at least on the measured advance of the belt element 110. In some implementations, the controller 170 may also determine the amount of build material 210 present in the container 200, based on the position of the surface 220 and the geometry of the container 200.
In implementations in which the controller 170 controls the motor 150, the controller may also de-energize the motor 150.
A build material container 200 may comprise implementations of a system for measuring the amount of build material according to the present disclosure, for example it may comprise any of the systems disclosed above in relation with
As shown in
In some implementations, the build platform 250 is movable in vertical direction, as shown by arrow A in
In such a case, the system for measuring the amount of build material may comprise in some implementations a belt tensioner, such as very schematically indicated at 112, to maintain the tension of the belt element 110 when the build platform 250 is displaced and the distance between shafts 120 and 130 changes.
A belt tensioner 112 may comprise in some implementations one or more additional shafts, for example displaceable and loaded with a spring, to displace a length of belt element 110 horizontally within the space 205, or it may comprise for example a torsion spring associated with one of the shafts 120 or 130 if for example the shafts comprise drums and the belt element 110 is mounted with each end wound around one of the drums. Other suitable solutions may also be provided.
In some implementations of a build material container 200 for a 3D printer with a displaceable build platform 250, the system for measuring the amount of build material may comprise additional shafts that are positioned to mount the belt element 110 around them in such a way that it extends partly inside the container 200, in the space 205, and partly outside the container 200, and in such a way that the length of the belt element 110 may remain substantially constant when the build platform 250 is displaced.
For example, some implementations of a build material container 200 are illustrated in
In some implementations the build material container 200 with build platform 250 may be provided on a trolley or building unit that may be docked in a 3D printer and withdrawn for loading and unloading operations.
In some implementations, the system for measuring the amount of build material may comprise the belt element 110, the shaft 120 attached to the platform 250, and the shaft 130 attached below the base of the container 200, and it may comprise additional shafts 122, 124, 126 and 128, around which the belt element 110 is mounted in closed loop for example as shown in
In implementations such as shown in
A suitable vertical groove (not shown) may be provided in the wall of the build material container 200 so that the belt element 110 may pass therethrough.
In the passage between the positions of
The motor 150, sensor 160 and controller 170 have been omitted from
In implementations comprising a system for measuring the amount of build material as disclosed in relation to
Some implementations of a method as disclosed above in relation to
The build material compacting operation at 545 may comprise in some implementations lifting the body from the surface of build material and driving it back towards the surface of the build material, such as illustrated by the schematic view of
Implementations of the method involving a compacting operation may provide more accurate and consistent determinations of the position of the surface 220 of the build material 210, and therefore of the amount of build material 210 present in the build material container 200.
An example method according to implementations disclosed in relation with
In some implementations a compacting operation may be performed once, or a predetermined number of times, or it may be repeated until for example the decrease in speed when the body 140 reaches the surface 220, determined by the controller 170, is substantially the same before and after a compacting operation.
In other implementations it is possible to perform several compacting operations and determine the position of the surface 220 of the build material 210 after each, until the surface of the material becomes stabilized. For example, the surface may be considered stabilized when the position of the surface 220 determined by the controller 170 before and after a compacting operation is substantially the same.
At the end of a compacting operation the controller 170 may determine the position of the surface of the build material, by taking into account the subsequent advances of the belt element 110 and the body 140 in both directions (arrows E and F in
Although a number of particular implementations and examples have been disclosed herein, further variants and modifications of the disclosed devices and methods are possible. For example, not all the features disclosed herein are included in all the implementations, and implementations comprising other combinations of the features described are also possible.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/058687 | 10/25/2016 | WO | 00 |