Methods and apparatus for 3D printing

• US 20050280185A1
• Filed: 04/01/2005
• Published: 12/22/2005
• Est. Priority Date: 04/02/2004
• Status: Abandoned Application

• Current Assignee: Z CORPORATION (A Holdings Corp.)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Russell, David, Hernandez, Andres, Berlin, Andrew, Kinsley, Joshua
• Application Number:
  US11/097,987
• Publication Number:
  US 20050280185A1
• Time in Patent Office: Days
• US Class Current: 264/308
• 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 7/465 Applying setting liquid to dry mixtures
• 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

Abstract

The invention relates to methods and apparatus for fabricating a three-dimensional object from a representation of the object stored in memory. The apparatus includes a stationary build table for receiving successive layers of a build material and at least one movable printhead disposed above the build table. The printhead deposits a binding material in a predetermined pattern on each successive layer of the build material to form the three-dimensional object.

Claims

1. An apparatus for fabricating a three-dimensional object from a representation of the object stored in memory, the apparatus comprising:

a stationary build table for receiving successive layers of a build material; and

at least one printhead disposed above the build table for selectively applying binder.

2. The apparatus of claim 1 further comprising means for supplying powdered build material to the build table.

3. The apparatus of claim 1 further comprising means for positioning the at least one printhead in a three dimensional space above the build table.

4. The apparatus of claim 1 further comprising an enclosure disposed about the stationary build table.

5. The apparatus of claim 4 further comprising an air handling system, the air handling system comprising:

at least one air intake port disposed through a wall of the enclosure; and

an exhaust system in communication with an interior area of the enclosure for drawing air out of the enclosure.

6. The apparatus of claim 5, wherein the air handling system further comprises filtration means.

7. The apparatus of claim 1 further comprising a build material delivery system comprising:

a storage means for holding the build material; and

a conveying means for delivering the build material to the build table.

8. The apparatus of claim 7 further comprising:

at least two storage chambers for holding at least two build material components separate from each other; and

a blender for mixing the build material components in a predetermined ratio for delivery to the build table.

9. The apparatus of claim 1 further comprising a build material dispensing system, the system comprising:

a trough for receiving the build material, the trough mounted on a gantry capable of traversing at least a portion of the build table; and

metering means for dispensing the build material.

10. The apparatus of claim 9, wherein a delivery dimension of the build material dispensing system is adjustable to correspond to a width of a predetermined build volume.

11. The apparatus of claim 9 further comprising spreading means for distributing the dispensed build material evenly to form a layer.

12. The apparatus of claim 11, wherein the spreading means comprises a range of travel adjustable to correspond to a length of a predetermined build volume.

13. The apparatus of claim 11 further comprising a sensor for determining an amount of build material deposited in each layer.

14. The apparatus of claim 9, wherein the dispensing system further comprises a translating nozzle for delivering the build material to the trough.

15. The apparatus of claim 9 further comprising a sensor for measuring the distribution of build material in the trough.

16. The apparatus of claim 3, wherein the printhead is mounted in a carrier, the carrier being mounted in a carriage.

17. The apparatus of claim 16, wherein the carrier engages mechanical, electrical, and fluid interfaces of the printhead.

18. The apparatus of claim 16, wherein the carrier engages mechanical, electrical, and fluid interfaces of the carriage.

19. The apparatus of claim 16 further comprising a printhead stable capable of housing at least one spare printhead, the stable comprising means for interchanging printheads for use with the apparatus.

20. The apparatus of claim 16 further comprising a printhead reconditioning station for performing printhead maintenance.

21. The apparatus of claim 16 further comprising a carrier transfer means for transferring the printhead between the carriage and the stable.

22. The apparatus of claim 1 further comprising printhead reconditioning means.

23. The apparatus of claim 3 further comprising means for moving the printhead in a vertical direction, the means comprising at least one jack post for supporting the gantry, the jack post including a lead screw, a lead screw nut, and a motor for driving the lead screw.

24. The apparatus of claim 23 further comprising an encoder for determining a position of the lead screw nut.

25. The apparatus of claim 3 further comprising a gantry for moving the printhead in a first horizontal direction.

26. The apparatus of claim 25, wherein the gantry is positioned in the first horizontal position by at least one of at least one motor-driven belt and at least one motor-driven lead screw.

28. The apparatus of claim 3 further comprising a carriage for moving the printhead in a second horizontal direction.

29. The apparatus of claim 28, wherein the carriage is positioned in the second horizontal position by at least one of at least one motor-driven belt and at least one motor-driven lead screw.

27. (canceled)

30. (canceled)

31. A method of fabricating a three-dimensional object comprising the steps of:

depositing successive layers of a build material on a stationary build table; and

depositing a liquid in a predetermined pattern on each successive layer of the build material to form the three-dimensional object.

32. The method of claim 31 further comprising the step of:

circumscribing the three-dimensional object with additional liquid to form a wall about the three-dimensional object.

33. The method of claim 32, wherein the wall and the table define a build volume.

34-43. -43. (canceled)

44. An apparatus for reconditioning a printhead, the apparatus comprising:

a nozzle array for spraying a washing solution towards a face of a printhead; and

a wicking member disposed in proximity to the printhead face for removing excess washing solution from the printhead face.

45-53. -53. (canceled)

54. A method of reconditioning a printhead, the method comprising the steps of:

positioning a face of the printhead relative to at least one nozzle;

operating the at least one nozzle to spray washing solution towards the printhead face; and

removing excess washing solution from the printhead face by passing a wicking member in close proximity to the printhead face, without contacting the printhead face.

55-58. -58. (canceled)