Patent Application
20160107392
Systems and methods herein generally relate to three-dimensional printing and finishing, and to communication systems.
Conventional three-dimensional (3-D) printing is characterized as “additive” manufacturing, which means that a solid, three-dimensional object is constructed by adding material in layers. This is in contrast to “subtractive” manufacturing, through which an object is constructed by cutting (or “machining”) raw material into a desired shape. 3-D printer processes vary, but the material is usually sprayed, squeezed, or otherwise transferred from the printer onto a platform.
The first stage of 3-D printing is laying out an object's design with software, such as computer-aided design (CAD) or animation modeling software. Such software allows one to create a virtual blueprint of the object one wants to print. The software then automatically divides the designed object into digital cross-sections, which the printer builds layer by layer. The cross-sections essentially act as guides for the printer, so that the object is the exact size and shape designed.
After the finished design file is sent to the 3-D printer, one chooses a specific material. Different print heads can add different materials to the object being created (e.g. rubber, plastics, paper, polyurethane-like materials, metals, and more). Then, the 3-D printer makes passes (much like an inkjet printer) over the platform, depositing layer on top of layer of material to create the finished product.
Presently three-dimensional printed objects are typically finished, coated or painted in a completely offline, manually initiated process that is not in communication with the printer.
Exemplary systems herein include, among other components a three-dimensional (3-D) printer creating 3-D items based on 3-D printing information, and a 3-D finishing device operatively (meaning directly or indirectly) connected to the 3-D printer. The finishing device performs finishing operations on the 3-D item based on finishing information.
Also, such systems include a communications device that is operatively connected to the 3-D printer and the finishing device. The communications device can comprise one or more devices, such as stand-alone computers, print servers, or custom circuit boards with special-purpose circuitry (such as application specific integrated circuits (ASIC) devices); and such device(s) can be separate devices, or can be integral with the 3-D printer and/or the 3-D finisher device. The communications device automatically provides the 3-D printing information to the 3-D printer, provides the finishing information to the 3-D finishing device, and provides two-way status information updates between the 3-D printer and the 3-D finishing device.
For example, the finishing information can comprise command signals and status signals. The status signals can be status information of the process of creating the 3-D item. The command signals can be instructions of finishing operations to be performed on the 3-D item.
In detail, the communications device transmits the finishing information from the 3-D printer to the 3-D finishing device at any time after the printing/finishing instructions are created, such as during the time period between when the 3-D printer begins creating the 3-D item and when the 3-D printer completes creating the 3-D item. In some limited examples, the finishing information can include the dimensions of the 3-D item, instructions to begin cycle-up processes of one or more finishing devices, requests for progress status of finishing operations, requests for ready state, consumable supply levels, and failure status states of the one or more finishing devices, etc.
In various methods herein the 3-D printer (or the special-purpose communications device) receives the 3-D printing information. The 3-D printer automatically creates the 3-D item based on the 3-D printing information. These methods also automatically provide finishing information to a 3-D finishing device using the special-purpose communications device. The 3-D finishing device automatically performs finishing operations on the 3-D item based on the finishing information, and, again, the communications device is operatively connected to the 3-D printer and the 3-D finishing device. Further, such methods automatically provide two-way status information updates between the 3-D printer and the 3-D finishing device using the special-purpose communications device.
Again, the finishing information comprises command signals and status signals, the status signals comprise status information of the progress of the creating the 3-D item, the command signals comprise instructions of finishing operations to be performed on the 3-D item, etc. The process of transmitting the finishing information transmits the finishing information from the 3-D printer to the 3-D finishing device at any time after the printing/finishing instructions are created, such as during the time period between when the 3-D printer begins creating the 3-D item and when the 3-D printer completes creating the 3-D item.
These and other features are described in, or are apparent from, the following detailed description.
Various exemplary systems and methods are described in detail below, with reference to the attached drawing figures, in which:
As mentioned above, three-dimensional printed objects are typically finished, coated, painted, etc., in a completely offline, manually initiated process that is not initiated by, or based on, any form of communication with the printer. Therefore, the systems and methods herein provide a 3-D digital finishing architecture (communication system) that uses information from the printer to set up a downstream finishing device, to allow the downstream finishing device to be ready to accept a 3-D printed piece and perform the appropriate function or functions to finish the workpiece accurately, in a timely manner, and without unnecessary wait time or finisher idle time (which could consume excess power needlessly).
The system of communication herein provides job parameters, such as the size of the workpiece, weight of the workpiece, as well as information about the desired finishing needed for the workpiece. The communication uses any industry standard communication protocol, such as but not limited to, universal serial bus (USB), Internet, controller area network bus (CANbus), etc. One benefit of using industry standard communication protocols is that it allows “plug and play” capabilities, so that the 3-D printer can understand what finishing capabilities are available. Systems herein allow finisher profile information (e.g., boundary conditions of each specific finishing device) with finishing constraints and timing requirements.
As shown in
In the exemplary implementation shown in
The input/output device 214 is used for communications to and from the communications device 200 and comprises a wired device or wireless device (of any form, whether currently known or developed in the future). The tangible processor 216 controls the various actions of the computerized device 200. A non-transitory, tangible, computer storage medium device 210 (which can be optical, magnetic, capacitor based, etc., and is different from a transitory signal) is readable by the tangible processor 216 and stores instructions that the tangible processor 216 executes to allow the computerized device 200 to perform its various functions, such as those described herein. Thus, as shown in
Therefore, as shown in
Also, such systems include one or more of the communications devices 200, and such is operatively connected to the 3-D printer 204 and the 3-D finishing device. The communications device 200 can comprise one or more devices, and such device(s) can be separate, stand-alone devices, or the communication device(s) 200 can be integral with the 3-D printer 204 and/or the finisher device 206. The computerized device 224 or the communications device 200 automatically provides the 3-D printing information to the 3-D printer 204, and the 3-D printer 204 or the communications device 200 automatically provides the finishing information to the finishing device; and the communications device 200 provides two-way status information updates between the 3-D printer 204 and the finishing device 206.
For example, the finishing information can comprise command signals and status signals. The status signals can be status information of the progress of the process of creating the 3-D item 230. The command signals can be instructions of finishing operations to be performed on the 3-D item 230. The computerized device 224 and/or communications device 200 can transmit the basic printing instructions and finishing instructions regarding what printing and finishing operations are to be performed, while only the communications device 200 allows the two-way status communication between the 3-D printer 204 and the one or more finishing devices 206. However, in one example that is used herein, the user is allowed to establish all printing and finishing instructions using the computerized device 224 (as a single job), and such a single job is sent only to the 3-D printer 204. After the 3-D printer receives such a single job, it can communicate aspects of the single job to the communications device 200, which then automatically calculates details of what finishing operations are available for the 3-D item produced by the single job, which finisher devices 206 will be used, when the finisher devices 206 should be powered-up or cycled-up, which automated transport equipment should be activated to automatically move the 3-D printed item to different finisher devices 206, etc.
Thus, as shown in
With systems herein, the user merely picks a specific finish (texture, color, etc.) for their 3-D design to include in the single job, and the communications device 200 automatically decides which finisher device(s) to utilize to achieve the selected finish (or a finish that is as close to the selected finish as possible with the finishing equipment that is available), calculates the order that the 3-D item 230 will be supplied to the different 3-D finishing devices 206, and calculates automated movement of the 3-D item 230 between the 3-D printer 204 and the finisher devices 206 that will obtain such a selected finish. Therefore, after the user sends the single job from the CAD program to the 3-D printer 204 and/or the communications device 200, the systems and methods herein calculate which devices are to be used, the order in which they shall be used, and automate all printing, transportation, and finishing processes to fully create and finish the 3-D item 230 without further user input or handling.
Further, by the communications device 200 providing two-way communications between the 3-D printer 204 and the finishers 206, the finishers are only cycled-up to a full power state when they will be used (thereby saving power by preventing unnecessary idling of finisher devices 206 at ready or full power states). Additionally, only finisher devices 206 that have the current capability to perform the finishing operations are chosen by the communications device 200 (e.g., only those finishing devices 206 that have sufficient consumables, do not have failure indicators, are not being utilized for other jobs, etc., are chosen by the communications device 200) to ensure timely completion of all jobs.
In detail, the communications device 200 transmits the finishing information from the 3-D printer 204 to the finishing device 206 at any time after the printing/finishing instructions are received, such as during the time period between when the 3-D printer 204 receives the job (or begins creating the 3-D item 230) and when the 3-D printer 204 completes creating the 3-D item 230. In some limited examples, the finishing information can include the dimensions of the 3-D item 230, instructions to begin cycle-up processes of one or more finishing devices, requests for progress status of finishing operations, requests for ready state, consumable supply levels, and failure status states of the one or more finishing devices, etc.
The lower half of
In item 302, the 3-D printer automatically creates the 3-D item based on the 3-D printing information. These methods also automatically provide finishing information to a finishing device using the special-purpose communications device in item 304. Again, the finishing information comprises command signals and status signals, the status signals comprise status information of the progress of the process of creating the 3-D item, the command signals comprise instructions of finishing operations to be performed on the 3-D item, etc. The process of transmitting the finishing information in item 304 transmits the finishing information from the 3-D printer to the finishing device at any time after the printing/finishing instructions are received, such as during the time period between when the 3-D printer begins creating the 3-D item and when the 3-D printer completes creating the 3-D item.
Further, such methods automatically provide two-way status information updates between the 3-D printer and the finishing device using the special-purpose communications device in item 306. The finishing device automatically performs finishing operations on the 3-D item based on the finishing information in item 308. As would be understood by those ordinarily skilled in the art, items 302-306 could be performed in any order, or could be performed in parallel (at the same time) and
While some exemplary structures are illustrated in the attached drawings, those ordinarily skilled in the art would understand that the drawings are simplified schematic illustrations and that the claims presented below encompass many more features that are not illustrated (or potentially many less) but that are commonly utilized with such devices and systems. Therefore, Applicants do not intend for the claims presented below to be limited by the attached drawings, but instead the attached drawings are merely provided to illustrate a few ways in which the claimed features can be implemented.
Many computerized devices are discussed above. Computerized devices that include chip-based central processing units (CPU's), input/output devices (including graphic user interfaces (GUI), memories, comparators, tangible processors, etc.) are well-known and readily available devices produced by manufacturers such as Dell Computers, Round Rock Tex., USA and Apple Computer Co., Cupertino Calif., USA. Such computerized devices commonly include input/output devices, power supplies, tangible processors, electronic storage memories, wiring, etc., the details of which are omitted herefrom to allow the reader to focus on the salient aspects of the systems and methods described herein. Similarly, printers, copiers, scanners and other similar peripheral equipment are available from Xerox Corporation, Norwalk, Conn., USA and the details of such devices are not discussed herein for purposes of brevity and reader focus. Further, the terms automated or automatically mean that once a process is started (by a machine or a user), one or more machines perform the process without further input from any user.
It will be appreciated that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. Unless specifically defined in a specific claim itself, steps or components of the systems and methods herein cannot be implied or imported from any above example as limitations to any particular order, number, position, size, shape, angle, color, or material.
