Material manipulation in three-dimensional printing

• US 10,449,696 B2
• Filed: 03/27/2018
• Issued: 10/22/2019
• Est. Priority Date: 03/28/2017
• Status: Active Grant

• Current Assignee: Velo3D, Inc.
• Original Assignee: Velo3D, Inc.
• Inventors: Elgar, Yacov, Brezoczky, Thomas Blasius, Frechman, James, Lappen, Alan Rick
• Primary Examiner(s): Lazorcik, Jason L
• Application Number:
  US15/937,798
• Publication Number:
  US 20180281236A1
• Time in Patent Office: 574 Days
• CPC Class Codes: B01D 45/16 generated by the winding course of the gas stream , the centrifugal forces being generated solely or partly by mechanical means, e.g. fixed swirl vanes
• CPC Class Codes: B01D 46/0002 Casings; Housings; Frame constructions
• CPC Class Codes: B01D 46/0053 with vibrating filtering elements
• CPC Class Codes: B01D 46/10 Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
• CPC Class Codes: B01D 50/20 Combinations of devices covered by groups B01D45/00 and B01D46/00
• CPC Class Codes: B04C 2009/002 with external filters
• CPC Class Codes: B04C 9/00 Combinations with other devices, e.g. fans, expansion chambers, diffusors, water lockswith filters B01D50/00
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/366 Scanning parameters, e.g. hatch distance or scanning strategy
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/30 Platforms or substrates
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 12/43 pulsed; frequency modulated
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2201/00 Treatment under specific atmosphere
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/005 Loading or unloading powder metal objects transport in general B65G
• 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 13/02 : Feeding the unshaped material to moulds or apparatus for producing shaped articles
• CPC Class Codes: B29C 31/085 : combined with positioning the preforms according to predetermined patterns, e.g. positioning extruded preforms on conveyors B29C70/30 takes precedence; for building tyres B29D30/08
• CPC Class Codes: B29C 64/135 : the energy source being concentrated, e.g. scanning lasers or focused light sources
• 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 64/176 : Sequentially
• 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 64/245 : Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• 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 64/307 : Handling of material to be used in additive manufacturing
• CPC Class Codes: B29C 64/321 : Feeding
• CPC Class Codes: B29C 64/35 : Cleaning
• CPC Class Codes: B29C 64/357 : Recycling
• 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 64/393 : for controlling or regulating additive manufacturing processes
• 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 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 systems, apparatuses, software, and methods for the production of at least one requested 3D object. The 3D printer includes a material conveyance system, filtering system, and unpacking station. The material conveyance system may transport pre-transformed material against gravity. The 3D printing described herein comprises facilitating non-interrupted material dispensing through a component of the 3D printer, such as a layer dispenser.

Claims

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

an enclosure configured to accommodate the three-dimensional object during printing;

a vertically translatable platform configured to support the at least one three-dimensional object during printing of the at least one three-dimensional object, which platform is disposed in the enclosure;

a compressed gas source configured to flow a gas in a direction;

a material reservoir having (i) at least one first wall that encloses a first volume configured to hold a first atmosphere having (A) a gas content different from an ambient atmosphere and (B) a first pressure, and (ii) a first material port disposed in the at least one first wall and configured to facilitate transport of a pre-transformed material therethrough, which material reservoir is operatively coupled to the enclosure and is configured to facilitate supply of the pre-transformed material to the enclosure to print the at least one three-dimensional object;

a bulk reservoir configured to hold a second atmosphere having (a) a second pressure above the first pressure and (b) a gas content different from an ambient atmosphere, which bulk reservoir comprises a second material port, a gas port, and at least one second wall that encloses a second volume configured to accommodate the pre-transformed material,

a storage container comprising a gas storage inlet, which storage container is configured to operatively couple to the first material port of the material reservoir;

a sieve assembly comprising a sieve inlet port, which sieve assembly is disposed between the bulk reservoir and the material reservoir;

which compressed gas source is operatively coupled to the bulk reservoir through the gas port to facilitate pressurized conveyance of the pre-transformed material from the bulk reservoir through the second material port to the first material port at least in part against a gravitational field; and

one or more controllers that are operatively coupled to the compressed gas source, which one or more controllers are configured to;

(i) direct pressurized transport of the pre-transformed material from the bulk reservoir to the material reservoir against the gravitational field, wherein the pressurized transport comprises transport through the sieve inlet port for sieving at least part of the pre-transformed material,

(ii) direct addition of the pre-transformed material to the material reservoir through the first material port, which first material port is configured to accept pre-transformed material from the storage container during printing of the three-dimensional object; and

(iii) direct flow of the gas from the compressed gas source through the gas storage inlet of the storage container to establish a third atmosphere that has (I) a third gas content that is different from an ambient atmosphere and (II) a third pressure.

2. The apparatus of claim 1, wherein the pressurized conveyance of the pre-transformed material comprises dense phase conveyance.

3. The apparatus of claim 1, wherein during the printing comprises without interruption of the printing, and/or without interruption of conveyance against the gravitational field, which conveyance is of the pre-transformed material to the material reservoir.

4. The apparatus of claim 3, wherein without interruption comprises printing continuously for at least 8 hours.

5. The apparatus of claim 1, wherein the one or more controllers are programmed to adjust the first atmosphere and/or the second atmosphere in response to a detection of one or more sensors, which one or more sensors are configured to detect at least one characteristic of the first atmosphere and/or of the second atmosphere.

6. The apparatus of claim 5, wherein the at least one characteristic of the first atmosphere and/or of the second atmosphere comprises (I) a pressure differential between the first atmosphere and the second atmosphere and/or (II) an atmospheric level of a reactive agent.

7. The apparatus of claim 6, wherein the reactive agent is reactive with a reactant and/or with a product of the printing.

8. The apparatus of claim 6, wherein the one or more controllers are configured to adjust the pressure differential between the first atmosphere and the second atmosphere such that the first pressure is higher than the second pressure.

9. The apparatus of claim 1, wherein the material reservoir comprises one or more sensors, which one or more sensors are operable to detect a level, type, and/or volume of pre-transformed material in the material reservoir.

10. The apparatus of claim 9, further comprising a valve that is operable to open in response to a level of the pre-transformed material, as detected by the one or more sensors, is below a threshold level.

11. The apparatus of claim 1, wherein the material reservoir comprises one or more sensors, which one or more sensors are operable to detect a reactive species in the material reservoir.

12. The apparatus of claim 1, wherein the enclosure comprises a third material port configured to accept the pre-transformed material from the material reservoir during the printing without interruption to the printing of the at least one three-dimensional object, and/or without interruption of the pressurized conveyance.

13. The apparatus of claim 12, wherein without interruption to the printing comprises printing continuously for at least 8 hours.

14. The apparatus of claim 1, wherein printing the at least one three-dimensional object comprises printing at a rate of at least 45 cubic centimeters per hour (cc/hr).

15. The apparatus of claim 1, wherein the at least the one first wall and/or the at least the one second wall are hermetically sealed and/or comprise a sealant, wherein the first volume and/or the second volume are configured to hold a positive pressure with respect to an ambient pressure.

16. The apparatus of claim 1, further comprising a recycling system coupled with an outlet port of the enclosure, which recycling system is configured to (i) receive a mixture of an excess pre-transformed material and a debris from the printing through the outlet port, and (ii) separate at least part of the debris from the excess pre-transformed material by cyclonic separation.

17. The apparatus of claim 16, further comprising a material remover that is configured to remove the mixture at least in part by (i) attracting a gas and the excess pre-transformed material into an internal volume of the material remover and (ii) cyclonically separating the excess pre-transformed material from the gas in the material remover.

18. The apparatus of claim 1, wherein the sieve assembly comprises an outlet opening configured to facilitate conveyance of sieved pre-transformed material to a respective storage inlet port of at least two storage containers.

19. The apparatus of claim 18, wherein the one or more controllers are programmed to direct conveyance of pre-transformed material to the material reservoir from a storage container of the at least two storage containers that is not receiving pre-transformed material from the bulk reservoir and/or the sieve assembly.

20. The apparatus of claim 19, wherein the one or more controllers are programmed to alternate conveying from a first storage container of the at least two storage containers to a second storage of the at least two storage containers considering a level of the pre-transformed material in the first storage container, which level is detected by a sensor operatively coupled with the one or more controllers.

21. A method for printing at least one three-dimensional object, comprising:

(1) providing an apparatus comprising;

an enclosure configured to accommodate the three-dimensional object during printing;

a vertically translatable platform configured to support the at least one three-dimensional object during printing of the at least one three-dimensional object, which platform is disposed in the enclosure;

a compressed gas source configured to flow a gas in a direction;

a material reservoir having (i) at least one first wall that encloses a first volume configured to hold a first atmosphere having (A) a gas content different from an ambient atmosphere and (B) a first pressure, and (ii) a first material port disposed in the at least one first wall and configured to facilitate transport of a pre-transformed material therethrough, which material reservoir is operatively coupled to the enclosure and is configured to facilitate supply of the pre-transformed material to the enclosure to print the at least one three-dimensional object;

a bulk reservoir configured to hold a second atmosphere having (a) a second pressure above the first pressure and (b) a gas content different from an ambient atmosphere, which bulk reservoir comprises a second material port, a gas port, and at least one second wall that encloses a second volume configured to accommodate the pre-transformed material,

a storage container comprising a gas storage inlet, which storage container is configured to operatively couple to the first material port of the material reservoir;

a sieve assembly comprising a sieve inlet port, which sieve assembly is disposed between the bulk reservoir and the material reservoir;

which compressed gas source is operatively coupled to the bulk reservoir through the gas port to facilitate pressurized conveyance of the pre-transformed material from the bulk reservoir through the second material port to the first material port at least in part against a gravitational field; and

one or more controllers that are operatively coupled to the compressed gas source, which one or more controllers are configured to;

(i) direct pressurized transport of the pre-transformed material from the bulk reservoir to the material reservoir against the gravitational field, wherein the pressurized transport comprises transport through the sieve inlet port for sieving at least part of the pre-transformed material,

(ii) direct addition of the pre-transformed material to the material reservoir through the first material port, which first material port is configured to accept pre-transformed material from the storage container during printing of the three-dimensional object; and

(iii) direct flow of the gas from the compressed gas source through the gas storage inlet of the storage container to establish a third atmosphere that has (I) a third gas content that is different from an ambient atmosphere and (II) a third pressure; and

(2) using the apparatus for printing the at least one three-dimensional object.

22. The method of claim 21, wherein the one or more controllers are used to direct the pressurized transport of the pre-transformed material from the bulk reservoir to the material reservoir at least in part by directing usage of a dense phase conveyance of the pre-transformed material.

23. The method of claim 21, further comprising establishing the first pressure by flowing compressed gas from the compressed gas source into an internal volume of the material reservoir.

24. The method of claim 21, further comprising establishing the first pressure in the first volume of the material reservoir in response to the pre-transformed material being below a threshold level in the material reservoir.

25. The method of claim 24, further comprising holding the bulk reservoir at the second pressure, such that flowing the pre-transformed material from the bulk reservoir to the material reservoir commences upon establishing the first pressure in the first volume of the material reservoir.

26. The method of claim 21, wherein the first atmosphere and/or the second atmosphere comprise an inert atmosphere.

27. The method of claim 21, further comprising directing pressurized transport of a pre-transformed material from the bulk reservoir to the material reservoir without interruption to the printing of the at least one three-dimensional object.

28. The method of claim 27, wherein without interruption to the printing comprises printing continuously for at least 8 hours.

29. The method of claim 21, further comprising detecting a level, type, and/or volume of material in the material reservoir.

30. The method of claim 21, further comprising detecting a reactive species in the material reservoir.

31. The method of claim 21, wherein printing the at least one three-dimensional object is at a rate of at least 45 cubic centimeters per hour (cc/hr).