Three-dimensional printing and three-dimensional printers

• US 10,286,452 B2
• Filed: 06/27/2017
• Issued: 05/14/2019
• Est. Priority Date: 06/29/2016
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Buller, Benyamin, Murphree, Zachary Ryan, Romano, Richard Joseph, Brezoczky, Thomas Blasius, Lappen, Alan Rick, Martinson, Robert Michael
• Primary Examiner(s): Minskey, Jacob T
• Assistant Examiner(s): Tsui, Melody
• Application Number:
  US15/634,727
• Publication Number:
  US 20180001557A1
• Time in Patent Office: 686 Days
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/60 Treatment of workpieces or articles after build-up
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/222 for motion along a direction orthogonal to the plane of a layer
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/49 Scanners
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 12/82 Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
• CPC Class Codes: B22F 12/88 Handling of additively manufactured products, e.g. by robots
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2201/10 Inert gases
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B28B 17/0081 Process control
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/20 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B29C 64/25 Housings, e.g. machine housings
• CPC Class Codes: B29C 64/255 : Enclosures for the building material, e.g. powder containers
• CPC Class Codes: B29C 64/364 : Conditioning of environment
• CPC Class Codes: B29C 64/371 : using an environment other than air, e.g. inert gas
• CPC Class Codes: B29C 64/386 : Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 : Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 40/10 : Pre-treatment
• CPC Class Codes: B33Y 40/20 : Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for the production of at least one desired 3D object. The 3D printer system (e.g., comprising a processing chamber, build module, or an unpacking station) described herein may retain a desired (e.g., inert) atmosphere around the material bed and/or 3D object at multiple 3D printing stages. The 3D printer described herein comprises one or more build modules that may have a controller separate from the controller of the processing chamber. The 3D printer described herein comprises a platform that may be automatically constructed. The invention(s) described herein may allow the 3D printing process to occur for a long time without operator intervention and/or down time.

Claims

1. An apparatus for three-dimensional printing of at least one three-dimensional object, comprising:

an unpacking station configured to facilitate removal of at least a portion of a starting material of the at least one three-dimensional object from the at least one three-dimensional object subsequent to printing the at least one three-dimensional object using the starting material, which unpacking station comprises a first atmosphere; and

a build module configured to accommodate the at least one three-dimensional object and the starting material, which build module comprises a second atmosphere,

which unpacking station and the build module are configured to reversibly engage one another, wherein the first atmosphere differs in content from an ambient atmosphere at least when the unpacking station and the build module have reversibly engaged one another, wherein (i) the unpacking station is configured to seal the first atmosphere at pressure different from an ambient pressure, and/or (ii) the build module is configured to seal the second atmosphere at pressure different from the ambient pressure, at least during removal of the at least the portion of the starting material of the at least one three-dimensional object from the at least one three-dimensional object at the unpacking station.

2. The apparatus of claim 1, wherein the unpacking station and/or the build module are configured to facilitate pressure maintenance of the first atmosphere and/or the second atmosphere respectively to above ambient pressure during removal of the at least the portion of the starting material of the at least one three-dimensional object from the at least one three-dimensional object.

3. The apparatus of claim 1, wherein the unpacking station comprises a first opening that is reversibly sealable by a first lid, and wherein the build module comprises a second opening that is reversibly sealable by a second lid, wherein the first lid and the second lid are removable from the first opening and the second opening, respectively.

4. The apparatus of claim 3, wherein upon engagement of the unpacking station with the build module, the first lid and the second lid translate to facilitate (i) merging of the first atmosphere with the second atmosphere, (ii) transfer of the at least one three-dimensional object from the build module into the unpacking station (iii) merging of the first opening with the second opening, or (iv) any combination thereof.

5. The apparatus of claim 4, wherein the first lid and the second lid are configured to translate while being engaged.

6. The apparatus of claim 4, wherein the first lid is configured to engage with the second lid prior to being translated.

7. The apparatus of claim 4, wherein a first translation direction of the first lid has a horizontal and/or vertical component, and wherein a second translation direction of the second lid has a horizontal and/or a vertical component.

8. The apparatus of claim 4, further comprising a first actuator configured to translate the first lid, and a second actuator configured to translate the second lid.

9. The apparatus of claim 8, wherein the first actuator and/or the second actuator is coupled to a first shaft and/or second shaft, respectively.

10. The apparatus of claim 8, wherein the first actuator and/or the second actuator is part of a first robot and/or second robot, respectively.

11. The apparatus of claim 8, wherein the first actuator and/or the second actuator is part of a first pick-and-place system and/or second pick-and-place system, respectively.

12. The apparatus of claim 1, wherein the build module comprises an actuator that facilitates vertical translation of (i) a platform and/or (ii) the at least one three-dimensional object.

13. The apparatus of claim 1, wherein the build module comprises a platform, and wherein the platform is configured to vertically translate using a translation mechanism comprising an encoder, vertical guide post, vertical screw, horizontal screw, linear motor, bearing, shaft, or bellow.

14. The apparatus of claim 1, wherein the build module comprises a platform, and wherein the platform is configured to vertically translate using a translation mechanism comprising an optical encoder, magnetic encoder, wheel bearing, gas bearing, or a scissor jack.

15. The apparatus of claim 1, wherein the build module comprises a platform, and wherein the platform is configured to rotate, translate, tilt, vibrate, or any combination thereof.

16. The apparatus of claim 1, wherein the build module comprises a platform, and wherein the platform is configured to rotate, translate, tilt, and/or vibrate, at least during removal of the at least the portion of the starting material of the at least one three-dimensional object from the at least one three-dimensional object.

17. The apparatus of claim 16, wherein the unpacking station further comprises an additional build module that is configured to (I) accommodate the at least one three-dimensional object, (II) reversibly engage with the unpacking station, (III) accommodate a third atmosphere, (IV) translate to and/or from the unpacking station, or (V) any combination thereof.

18. The apparatus of claim 17, wherein the additional build module comprises a base that is configured to accommodate the at least one three-dimensional object after removal of the at least the portion of the starting material of the at least one three-dimensional object from the at least one three-dimensional object.

19. The apparatus of claim 17, wherein the additional build module comprises a third opening that is reversibly sealable by a third lid, wherein the third lid is reversibly removable from the third opening.

20. The apparatus of claim 1, wherein the unpacking station is configured to facilitate contacting and/or manipulating the at least one three-dimensional object from two or more spatial directions.

21. The apparatus of claim 20, wherein contacting comprises using an inanimate operator.

41. The apparatus of claim 1, wherein the first atmosphere and/or the second atmosphere comprises (1) an inert gas, and/or (2) less than a threshold concentration of a reactive agent, wherein at or above the threshold concentration, the reactive agent is reactive with the starting material and/or with at least a portion of the at least one three-dimensional object during printing of the at least one three-dimensional object.

43. The apparatus of claim 1, further comprising a seal that is:

(a) part of or operatively coupled to the unpacking station and configured to seal the first atmosphere, or (b) part of or operatively coupled to the build module and configured to seal the second atmosphere.

44. The apparatus of claim 1, wherein configured to seal the first atmosphere and/or the second atmosphere, is configured to gas tight seal the first atmosphere and/or the second atmosphere.

45. The apparatus of claim 1, wherein the second atmosphere differs in content from the ambient atmosphere.

47. The apparatus of claim 1, further comprising at least one controller that is operatively coupled to the unpacking station and/or build module, which at least one controller is configured to direct pressure maintenance in the first atmosphere to pressure above ambient pressure and/or the second atmosphere to pressure above ambient pressure, during removal of the at least the portion of the starting material of the at least one three-dimensional object from the at least one three-dimensional object.

22. An apparatus for three-dimensional printing of at least one three-dimensional object comprising at least one controller that is configured to operatively couple to an unpacking station, and/or a build module, which at least one controller is configured to direct at least the following operations:

(a) reversible engage (i) an unpacking station that is configured to accommodate a first atmosphere and is configured to facilitate removal of at least a portion of a starting material of the at least one three-dimensional object from the at least one three-dimensional object subsequent to printing the at least one three-dimensional object using the starting material and, with (ii) the build module that is configured to accommodate a second atmosphere, the at least one three-dimensional object, and a starting material of the at least one three-dimensional object; and

(b) control the first atmosphere to differ in content from an ambient atmosphere at least when the unpacking station and the build module have reversibly engaged with one another, and (i) seal the first atmosphere at pressure different from an ambient pressure, and/or (ii) seal the second atmosphere at pressure different from the ambient pressure, at least during removal of the at least the portion of the starting material of the at least one three-dimensional object from the at least one three-dimensional object at the unpacking station.

23. The apparatus of claim 22, wherein during removal of the at least the portion of the starting material, the at least one controller is configured to direct maintaining the pressure above the ambient pressure in the unpacking station and/or the build module.

24. The apparatus of claim 22, wherein the unpacking station comprises a first opening that is reversibly sealable by a first lid, wherein the build module comprises a second opening that is reversibly sealable by a second lid, wherein the first lid and/or the second lid is translatable.

25. The apparatus of claim 24, wherein upon and/or after engagement of the unpacking station with the build module, the at least one controller is collectively or separately configured to direct translation of the first lid and/or the second lid to facilitate (I) merging of the first atmosphere with the second atmosphere, (II) transfer of the at least one three-dimensional object from the build module into the unpacking station, (III) merging of the first opening with the second opening, (IV) coupling the first lid with the second lid, (V) translating the first lid and the second lid, or (VI) any combination thereof.

26. The apparatus of claim 22, wherein the build module engages with the unpacking station through a load lock.

27. The apparatus of claim 25, wherein the at least one controller is collectively or separately configured to direct translation of the first lid and/or the second lid, while the build module is engaged with the unpacking station.

28. The apparatus of claim 27, wherein the at least one controller is collectively or separately configured to direct an actuator to cause vertical translation (1) of a platform and/or (2) of the at least one three-dimensional object.

29. The apparatus of claim 28, wherein the at least one controller is collectively or separately configured to direct rotation, horizontal translation, tilting, and/or vibration, of the platform.

30. The apparatus of claim 27, wherein the at least one controller is collectively or separately configured to direct (I) transfer of the at least one three-dimensional object to an additional build module, (II) reversible engagement of the additional build module with the unpacking station, (III) maintenance of a third atmosphere in the additional build module, (IV) translation of the additional build module to and/or from the unpacking station, or (V) any combination thereof.

31. The apparatus of claim 30, wherein maintenance of the third atmosphere in the additional build module comprises maintenance of an atmosphere that (1) is above ambient pressure, (2) is inert, (3) is non-reactive with the starting material and/or at least a portion of the at least one three-dimensional object during printing of the at least one three-dimensional object, (4) comprises a reactive agent below a threshold, or (5) any combination thereof.

32. The apparatus of claim 30, wherein the at least one controller is collectively or separately configured to direct removal and/or reversible engagement of a third lid from or with a third opening of the additional build module, respectively.

33. The apparatus of claim 32, wherein the at least one controller is collectively or separately configured to direct removal and/or reversible engagement of a fourth lid from or with a fourth opening of the unpacking station, respectively.

34. The apparatus of claim 33, wherein the at least one controller is collectively or separately configured to direct engagement of the additional build module with the unpacking station.

35. The apparatus of claim 34, wherein the additional build module engages with the unpacking station by (I) merging the third opening with the fourth opening, (II) coupling the third lid to the fourth lid, (III) translating the third lid and the fourth lid, (IV) merging the first atmosphere and the third atmosphere, (V) translating the at least one three-dimensional object from the unpacking station to the additional build module, or (VI) any combination thereof.

36. The apparatus of claim 34, wherein the additional build module engages with the unpacking station through an additional load lock.

37. The apparatus of claim 22, wherein the at least one controller is collectively or separately configured to direct transfer of the at least one three-dimensional object to or from the unpacking station.

38. The apparatus of claim 22, wherein the at least one controller is collectively or separately configured to direct transfer of a base to or from the unpacking station, which base is part of the build module.

39. The apparatus of claim 30, wherein the at least one controller is collectively or separately configured to direct transfer of an additional base to or from the unpacking station, which additional base is part of the additional build module.

40. The apparatus of claim 30, wherein the first atmosphere, the second atmosphere, and/or the third atmosphere (a) is above ambient pressure, (b) is inert, and/or (c) comprises less than a threshold concentration of a reactive agent, or (d) any combination thereof, wherein at or above the threshold concentration, the reactive agent is reactive with the starting material and/or with at least a portion of the at least one three-dimensional object during printing of the at least one three-dimensional object.

42. The apparatus of claim 22, wherein the first atmosphere and/or the second atmosphere comprises (1) an inert gas, and/or (2) less than a threshold concentration of a reactive agent, wherein at or above the threshold concentration, the reactive agent is reactive with the starting material and/or with at least a portion of the at least one three-dimensional object during printing of the at least one three-dimensional object.

46. The apparatus of claim 22, wherein the second atmosphere differs in content from the ambient atmosphere.