A three-dimensional (3D) printing system can be used to form 3D objects. A 3D printing system performs a 3D printing process, which is also referred to as an additive manufacturing (AM) process, in which successive layers of material(s) of a 3D object are formed under control of a computer based on a 3D model or other electronic representation of the object. The layers of the object are successively formed until the entire 3D object is formed.
Some implementations of the present disclosure are described with respect to the following figures.
In a 3D printing system, a build material (or multiple different build materials) can be used to form a 3D object, by depositing the build material(s) as successive layers until the final 3D object is formed. In some examples, a build material can include a powdered build material that is composed of particles in the form of fine powder or granules. The powdered build material can include metal particles, plastic particles, polymer particles, or particles of other materials.
Build material(s) can be transported from a build material reservoir (or multiple build material reservoirs) of the printing system to a printing bed (or more simply “bed”) of the printing system, where layers of the build material(s) are formed on the bed. A build material is delivered in metered amounts and at specified temperatures. In example printing systems, the powdered build material can be spread in a plane along two perpendicular axes (such as an x axis and a y axis) across the printing bed. The printing bed can also be referred to as a build platform.
In accordance with some implementations of the present disclosure, a 3D printing system includes a build material delivery system that includes a moveable conveyor belt to carry a build material from a build material reservoir to a location of the printing system where the powdered material can be spread onto a printing bed of the printing system. The build material reservoir may be located below the printing bed.
The outer surface 110 of the belt 106 is used to carry a build material as the belt 106 circulates. A circulating belt refers to a belt that moves in a closed loop on a continual basis. In other examples, other types of moveable conveyor belts with other movement patterns can be used.
In the example of
The outer surfaces of the rollers 112, 114, and 116 engage an inner surface 118 of the belt 106. At least one of the rollers 112, 114, and 116 can be driven (rotated) by a motor (not shown in
The build material on the outer surface 110 of the belt 106 is transported to a delivery location (generally indicated as 120) where the build material is deposited generally as indicated by arrow 122 (due to gravity and the motion of the belt 108) onto an upper surface 125 of a moveable delivery platform 124. The powdered build material can be generally free flowing. The delivery platform 124 is moveable between a lowered position (the position shown in
As shown in
After the metered amount of the build material 126 has been deposited onto the upper surface 125 of the delivery platform 124, the belt 106 can be stopped, and an actuator 128 can be activated to raise the delivery platform 124 to the raised position. At the raised position, the upper surface 125 of the delivery platform 124 on which the deposited build material 126 is provided is substantially at the same height as the upper surface 104 of the printing bed 102. Being “substantially at the same height” can mean that the upper surface 125 of the delivery platform 124 and the upper surface 104 of the printing bed 102 are aligned so that the deposited build material 126 can be pushed onto the upper surface 104 of the printing bed 102 from the upper surface of the delivery platform 124. The upper surface 125 of the delivery platform 124 being at “substantially the same height” as the printing bed upper surface 104 can refer to the upper surfaces 125 and 104 being at exactly the same height, or the upper surfaces 125 and 104 being at different heights but within some specified distance of one another.
The combination of the belt 106, rollers 112, 114, and 116, the delivery platform 124, and the actuator 128 (along with other components, such as the motor to drive the roller 112, 114, and/or 116) can be collectively considered to be a build material delivery system that is useable within the printing system 100. The build material delivery system is to transport a build material from a build material reservoir below the printing bed 102 to a delivery location (e.g. 120 in
After the delivery platform 124 has been moved by the actuator 128 to the raised position, a spreader (not shown in
In some examples, spreading of the deposited build material 126 onto the printing bed 102 has to occur along just the single spreading axis 130, such that spreading along multiple axes does not have to be performed. Spreading in just one spreading axis simplifies the design of the printing system 100 by eliminating certain moving parts, and can make the printing operation more efficient.
A top view of the 3D printing system 100 of
The outer surface 110 of the belt 106 has a width W1, and the printing bed upper surface 104 has a width W2. Each of the widths W1 and W2 extend along an axis that is perpendicular to the spreading axis 130 of the deposited build material 126. In one example, the width W1 of the outer surface 110 of the belt 106 is substantially equal to the width W2 of the upper surface 104 of the bed 102. The widths W1 and W2 may be considered substantially equal if the widths are within 5%, 10%, 15%, or 20% of each other. W1 can be greater than W2, equal to W2, or less than W2.
Although not shown, the width of the upper surface 125 of the delivery platform 124 can also be substantially equal to the width W2 of the upper surface 104 of the printing bed 102.
A conveyor belt 306 of the printing system 300 differs from the conveyor belt 106 of
A plan view of a portion of the belt 306 is shown in
As further shown in
Also, the housing 308 serves to level the build material in each cavity 304 such that a build material portion that fills the cavity 304 is level with the height of the transport structures 302. As a result, a uniform slug of build material is provided in each cavity 304, so that more accurate metering of a build material can be achieved when delivering the build material to the delivery platform 124. The metering can be accomplished by operating the belt 306 for a specified time interval, or based on emptying the content of a specified number of cavities 304 onto the delivery platform. The uniform slug of build material in each cavity 304 has a known volume, based on the distance of the spacing between successive transport structures 302, and based on the depth of the cavity, so that the printing system 300 can determine how much build material is deposited based on distance traveled by the belt 306 (or equivalently based on an amount of rotational movement of a roller 112, 114, or 116).
Although not explicitly shown in
At least one of the rollers 112, 114, and 116 can have an outer surface with a gear profile (in the form of a toothed wheel), where protrusions of the geared outer surface(s) of the roller(s) can engage the teeth profile of the inner surface 318 of the belt 306, such that the belt 306 can be moved by rotation of the roller(s).
Another roller 312 is provided to engage the outer surface 310 of the belt 306 in the return path 303 of the belt 306. The roller 312 can have an outer surface with a gear profile to engage the teeth profile provided on the outer surface 310 of the belt 306 by the transport structures 302 and cavities. In some examples, the rollers 112, 114, and 116 can each have a gear profile similar to that of the roller 312.
The roller 312 is positioned to push one side of the belt 306 inwardly (in a direction indicated by 314) towards the other side of the belt 306. The presence of the roller 312 defines a recessed contour in the portion of the belt 306 against which the roller 312 is engaged. The recessed portion of the belt 306 moves away from the delivery platform 124 after passing the delivery platform 124.
The printing system 300 also includes the spreader 202, which is moveable along the spreading axis 130 after the delivery platform 124 has been moved to the raised position. In examples according to
Any excess build material that is pushed by the spreader 202 across the printing bed upper surface 104 can be provided to a return chute 318, as indicated generally by arrow 320.
After the deposited build material 126 has been spread by the spreader 202 from the upper surface 125 of the delivery platform 124 to the printing bed upper surface 104, the delivery platform 124 can be moved from the raised position to the lowered position. Movement of the belt 306 can then be activated again, which causes a further portion of the build material to be delivered from the belt 306 to the delivery platform 124 in the lowered position. The delivery platform 124 can then be raised again to the raised position to allow the further portion of the build material to be spread by the spreader 202 to the printing bed upper surface 304.
Once a layer of the deposited build material 126 is formed on the printing bed upper surface 104 due to the spreading of the build material from the delivery platform 124 to the printing bed upper surface 304, a printhead (or multiple printheads), which are not shown, can deposit a liquid agent (or other suitable material) onto selected portions of the spread build material on the printing bed upper surface 104. Any portions of the layer of the build material onto which the liquid agent or other material is deposited can have the particles glued together, or such portions are further processed to transform the portions from a powdered form to a solid form. In other examples, instead of depositing a liquid agent, portions of the layer of the printing material can be exposed to a laser beam to produce a target image. In further examples, other types of processing can be applied to the layer of build material on the printing bed upper surface 104.
The depositing of the liquid agent can be based on a model of the 3D object that is to be formed, and can be controlled by a computer of the printing system 300. According to the 3D object model, the liquid agent can be deposited onto portions of the layer of build material to form a corresponding layer of the 3D object. Any unbound portion (a portion on which the liquid agent has not been deposited) of the build material on the printing bed upper surface 104 remains in powdered form, and can be removed in a process referred to as de-powdering. Any de-powdered build material can also be returned through the return chute 318.
The return chute 318 leads to a passageway 322 that extends to a build material reservoir 324 of the printing system 300. The reservoir 324 is arranged to store a build material that is to be transported by the conveyor belt 306 to the printing location 120 for delivery to the delivery platform 124.
Although just one build material reservoir 324 is shown in
As further shown in
The inner housing 326 has a lower opening 328 through which the build material in the reservoir 324 can pass to the cavities 304 of the belt 306, generally along a direction indicated by arrow 325.
The printing bed 102 is attached to a piston 330 (or other support), where the piston 330 is moveable up and down on a piston rod 332. The piston rod 332 is surrounded by an outer shroud 334, to isolate the piston rod 332 from the build material in the reservoir 324. A motor 336 controls the up and down motion of the piston 330 on the piston rod 332.
As successive layers of build material are formed on the printing bed upper surface 104, the motor 336 can be actuated to lower the printing bed 102 by respective incremental amounts to corresponding different elevations, so that each successive layer of build material can be formed over the previously formed build material layer.
As further shown in
In other examples, the heater 340 can be attached to a different structure. The target temperature of the build material can be controlled by controlling the heater 340.
In other examples, a heater (or multiple heaters) can be provided at different locations for heating the build material on the belt 306, such as at locations shown in
In examples according to
In examples according to
Rotation of the roller 508 causes a corresponding rotation of the roller 506 which in turn engages the surface 504 of the gear rack 502 to cause movement of the gear rack 502 along the diagonal axis 305 as the roller 506 rotates. A counter clockwise rotational movement of the roller 506 causes a generally downward movement of the gear rack 502 along the diagonal axis 305. A clockwise rotational movement of the roller 506 causes the gear rack 502 to move upwardly along the diagonal axis 305.
A diagonal support wall 510 is provided along which the delivery platform 124 is moveable, until the delivery platform 124 is raised to its raised position such that the upper surface 125 of the delivery platform 124 is aligned with the printing bed upper surface 104.
As further shown in
The film heaters 608 when activated can heat the outer housing 308 (
By using a combination of the heating lamp 340 and the film heaters 608, a combination of heating techniques in different zones can be used. For example, heat conduction applied by the film heaters 608 can apply a shear force on the powdered build material as the powdered build material is dragged across a heated surface, e.g. the inner surface of the outer housing 308. Above certain temperatures, the powdered build material may not be able to support this shear force and may fuse or clump together. The powdered build material can be heated by conduction (such as with use of the film heater 608) until the temperature of the powdered build material reaches a threshold temperature. Once the heated powdered material that has been heated to the threshold temperature reaches a zone adjacent the heating lamp 340, then further heating can be applied by the heating lamp 340. By using a combination of heating techniques, the overall heating cost can be reduced since the cost of using heating lamps can be higher than the use of film heaters or other types of conductive heating elements.
The process includes positioning (at 706) a moveable delivery platform (e.g. 124 in
In the foregoing description, numerous details are set forth to provide an understanding of the subject disclosed herein. However, implementations may be practiced without some of these details. Other implementations may include modifications and variations from the details discussed above. It is intended that the appended claims cover such modifications and variations.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/028876 | 4/22/2016 | WO | 00 |