Apparatus, systems and methods for use in three-dimensional printing

• US 20040004303A1
• Filed: 07/03/2002
• Published: 01/08/2004
• Est. Priority Date: 07/03/2002
• Status: Active Grant

• Current Assignee: Theken Spine LLC (Orthofix Medical Inc.)
• Original Assignee: Therics Inc.
• Inventors: Iskra, James P.
• Granted Patent: US 6,905,645 B2
• Time in Patent Office: Days
• US Class Current: 264/109
• CPC Class Codes: B22F 10/22 Direct deposition of molten metal
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/77 of gas
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/226 for rotary motion
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 12/55 Two or more means for feeding material
• CPC Class Codes: B22F 12/63 Rollers
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B22F 12/84 Parallel processing within single device
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2043/3494 using vibrating means
• CPC Class Codes: B29C 35/0288 Controlling heating or curing of polymers during moulding, e.g. by measuring temperatures or properties of the polymer and regulating the process controlling or regulating chemical, physical or physico- chemical processes in general B01J19/0006
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 41/46 Heating or cooling
• CPC Class Codes: B29C 41/52 Measuring, controlling or regulating
• CPC Class Codes: B29C 43/34 Feeding the material to the mould or the compression means B29C43/085 takes precedence
• 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: 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 50/00 : Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B41J 3/4073 : Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects B41J3/283, B41J3/286 take precedence; building up a 3D object using individual droplets from jetting heads B29C64/112
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

Apparatus, systems and methods for use in three-dimensional printing are shown and described. Various embodiments of the invention allow for more precise and controlled delivery of heat to achieve interlayer drying; isolation of the working region from the outside for reasons of cleanliness and in connection with the vapors of organic solvents; better control of the temperature of the working region; better accuracy in the flowrates of binder fluid dispensed; matching of delivered flowrates for multiple dispensers; verification of delivered flowrate or drops; provision for easier changeover of the machine from one powder to another; cleanability; and other needs.

Claims

1. A three-dimensional printing apparatus, comprising:

a powder layer depositor configured to deposit a layer of powder onto an operating surface;

a dispenser configured for dispensing a fluid, which comprises a volatile liquid, onto the layer of powder; and

a heat source configured to facilitate evaporation of the volatile liquid, the heat source being movable with respect to the operating surface between an operable position in which the heat source is proximate the layer of powder, and an inoperable position in-which the heat source is spaced apart from the layer of powder.

2. The apparatus of claim 1 wherein the heat source is moved by a motion apparatus which also moves the powder layer depositor.

3. The apparatus of claim 1 wherein the heat source is configured to remain stationary in the operable position while heat is applied to the powder.

4. The apparatus of claim 1 wherein the heat source is configured to move into the operable position, to remain stationary during application of heat to the powder, and to move out of the operable position after the heat has been applied to the powder.

5. The apparatus of claim 1 wherein the heat source is smaller than a surface of the layer of powder and is configured to move with respect to the surface during application of heat.

6. The apparatus of claim 1 wherein the heat source comprises a radiant heater.

7. The apparatus of claim 6 wherein the heat source comprises a plurality of tubular heaters.

8. The apparatus of claim 6 wherein the radiant heater is oriented to direct thermal radiation at the layer of powder when it is in the operable position.

9. The apparatus of claim 1 wherein the heat source is controllable to discharge a heated gas.

10. The apparatus of claim 1 wherein the heat source comprises a radiant heater and is controllable to discharge a heated gas.

11. The apparatus of claim 1 wherein the heat source comprises a housing configured to receive, circulate and exhaust a cooling gas to remove heat from the heat source.

12. The apparatus of claim 11 wherein the housing comprises a plurality of tubular heaters each enclosed in a transparent sleeve configured to allow the cooling gas to flow along the tubular heaters and remove heat from the heat source.

13. The apparatus of claim 11 wherein the housing comprises a flat enclosed region above the plurality of heaters, the flat enclosed region being configured to allow a cooling gas to flow through the flat enclosed region and remove heat from the heat source.

14. The apparatus of claim 11 further comprising a conduit configured to exhaust the cooling gas outside the three dimensional printing apparatus.

15. The apparatus of claim 11 wherein the apparatus is configured to controllably circulate the cooling gas through the heat source at some times and not at other times.

16. The apparatus of claim 1 wherein the powder layer depositor comprises a means for spreading powder.

17. The apparatus of claim 1 wherein the powder layer depositor comprises a slurry deposition system that is configured to deposit a slurry comprising the powder suspended in a carrier liquid.

18. The apparatus of claim 1 wherein the fluid is capable of dissolving the powder.

19. The apparatus of claim 1 wherein the fluid contains an agent capable of binding the powder together.

20. The apparatus of claim 1 wherein the fluid contains an active pharmaceutical ingredient.

21. The apparatus of claim 1 wherein the heat source is configured to operate for predetermined time durations.

22. The apparatus of claim 1 wherein the heat source is configured to operate in response to a signal from a control system.

23. A three-dimensional printing apparatus, comprising:

a powder layer depositor configured to deposit a layer of a powder onto an operating surface;

a printhead configured to dispense a fluid, which comprises a volatile liquid, onto the layer of the powder; and

a heat source controllable in response to a signal from a sensor configured to measure a property of the powder.

24. The apparatus of claim 23 wherein the sensor measures a temperature of the powder.

25. The apparatus of claim 23 wherein the sensor measures a content of the volatile liquid in the powder.

26. A method of three-dimensional printing, comprising the steps of:

depositing a layer of powder onto an operating surface;

dispensing onto the layer of powder a fluid comprising a volatile liquid;

moving a heat source into an operable position proximate the layer of powder; and

applying heat from the heat source to the layer of powder to facilitate evaporation of the volatile liquid.

27. The method of claim 26, further comprising, after applying heat to the layer of powder, dispensing more of the fluid onto the layer of powder.

28. The method of claim 26 wherein applying heat comprises performing radiant heating.

29. The method of claim 26 wherein applying heat comprises directing a heated gas toward the layer of powder.

30. The method of claim 26 wherein applying heat comprises applying heat until the, amount of the volatile liquid remaining in the powder has reached a desired value, the desired value being greater than zero.

31. The method of claim 26 wherein the heat source remains stationary as it applies heat to the layer of powder.

32. The method of claim 26 wherein the heat source moves as it applies heat to the layer of powder.

33. The method of claim 32 wherein applying heat to the layer of powder comprises heating one portion of the layer of powder while dispensing fluid onto another portion of the layer of powder.

34. The method of claim 26 wherein depositing the layer of powder comprises depositing a slurry comprising a carrier liquid, and further comprising applying heat to the layer of powder to facilitate evaporation of the carrier liquid.

35. A method of three-dimensional printing, comprising:

depositing a slurry comprising a carrier liquid and a powder;

moving a heater proximate the slurry;

applying heat to the slurry to facilitate evaporation of the carrier liquid and leave a layer of powder;

moving the heater away from the layer of powder; and

dispensing onto the layer of powder a fluid comprising a volatile liquid.

36. The method of claim 35, further comprising, after the dispensing of the fluid,

moving the heater proximate the layer of powder;

and

applying heat to the layer of powder to facilitate evaporation of the volatile liquid.