3D printer

• US 10,391,713 B2
• Filed: 02/06/2018
• Issued: 08/27/2019
• Est. Priority Date: 09/21/2016
• Status: Active Grant

• Current Assignee: Sergey Singov
• Original Assignee: Sergey Singov
• Inventors: Singov, Sergey
• Primary Examiner(s): Kessler, Christopher S
• Application Number:
  US15/889,664
• Publication Number:
  US 20180169956A1
• Time in Patent Office: 567 Days
• CPC Class Codes: B22D 23/06 Melting-down metal, e.g. metal particles, in the mould
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/43 characterised by material
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• CPC Class Codes: B22F 2007/066 using impregnation
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/115 by spraying molten metal, i.e. spray sintering, spray casting
• CPC Class Codes: B22F 7/008 characterised by the composition
• CPC Class Codes: B22F 7/06 of composite workpieces or articles from parts, e.g. to form tipped tools B22F7/002 takes precedence
• 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: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method for forming an object having a three-dimensional target shape, that makes use of a build powder, a support powder and a binder. The build powder is more strongly bound by the binder than is the support powder. The build powder and the support powder are dispensed in a sequence of layers of build powder patterned with support powder that collectively form the three-dimensional shape in build powder, and the binder is applied to the deposited build powder, thereby forming the object of build powder and binder. Finally, the formed object is separated from the support powder.

Claims

1. A method for forming an object having a three-dimensional target shape, comprising:

a) providing a build powder, a support powder and a binder;

wherein said build powder is wettable by said binder and said support powder is not wettable by the binder;

b) dispensing said build powder and said support powder in a sequence of layers of build powder patterned with support powder that collectively form the three-dimensional shape in build powder;

c) after said dispensing of said build powder and said support powder in a sequence of layers, applying the binder to at least the build powder, thereby forming said object, made of build powder and binder;

d) separating said object from said support powder; and

e) wherein said step of dispensing said build powder and said support powder in a sequence of layers is performed by an apparatus for making three-dimensional physical objects, comprising;

i) a frame;

ii) a container;

iii) a first support powder pourer, at least partially filled with support powder and a second support powder pourer, at least partially filled with support powder and a build powder pourer at least partially filled with build powder, each of said pourers having a dispensing opening and a dispensing plug, controllably covering said dispensing opening; and

iv) wherein said opening of said first support powder pourer is larger than said opening of said second support powder pourer, so that said first support powder pourer can pour support powder more quickly than said second support powder pourer and said second support powder pourer can dispense a finer line of support powder than said first support powder pourer; and

v) a pourer-movement and dispensing plug-actuating assembly supported by said frame over said container, and including a movement element that is selectively attachable to said build powder pourer and alternately to said support powder pourer and also capable to controllably move an attached pourer in three orthogonal dimensions and to control said dispensing plug; and

;

vi) a computing assembly, including an input for receiving a target three-dimensional shape, and controlling said pourer-movement and dispensing plug-actuating assembly to move said pourers and selectively open said plugs, thereby causing powder to be poured into said container, and to thereby create in said container a sequence of layers of build powder patterned with support powder that collectively form said target shape in build powder.

2. The method of claim 1, wherein the build powder and the support powder are pourable.

3. The method of claim 1, wherein the build powder and the support powder remain as solid particles when the binder is applied.

4. The method of claim 1, wherein the binder is heated to cause it to bind the build powder.

5. The method of claim 1, wherein the build powder is a metal powder and the binder is a molten metal.

6. The method of claim 1, wherein the build powder is a metal powder and the binder is a metal, and wherein the binder is applied in solid particle form followed by heating to a temperature sufficient to melt the binder.

7. The method of claim 1, wherein the build powder is iron powder, the support powder is silicon dioxide powder, and the binder is a molten iron-carbon alloy.

8. The method of claim 1, further comprising two or more build powders of different colors.

9. The method of claim 1 wherein said apparatus further includes a first refill tank and at least a second refill tank, and wherein said first and second refill tanks each have an associated docking station onto which a pourer may be docked and be physically supported and receive powder from said refill tank, and wherein said first refill tank contains build powder and said second refill tank contains support powder.

10. The method of claim 1 wherein said apparatus further comprises a third support powder pourer with an opening that is a third size that is larger than said first opening.

11. The method of claim 1 wherein said apparatus further includes a refill tank for each pourer.

12. The method of claim 1 wherein said pourers each include a plug rod and said pourer movement and dispensing plug actuating assembly includes a plug rod actuator that moves said plug rod up to open said opening and down to close said opening.

13. The method of claim 12, wherein said plug rod actuator also periodically rotates said plug rod, to stir the pourer contents.