System for creating 3D products

• US 20060030964A1
• Filed: 09/30/2005
• Published: 02/09/2006
• Est. Priority Date: 01/16/2003
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Silverbrook Research Pty Limited
• Inventors: Silverbrook, Kia
• Granted Patent: US 7,144,242 B2
• Time in Patent Office: Days
• US Class Current: 700/118
• CPC Class Codes: B05C 5/0212 only at particular parts of the articles at particular part of web, band, strip, belt or ribbon B05C5/025
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 12/20 Cooling means
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 12/70 Gas flow means
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: B41J 11/002 Curing or drying the ink on the copy materials, e.g. by heating or irradiating
• CPC Class Codes: B41J 11/0021 using irradiation
• CPC Class Codes: B41J 11/00214 using UV radiation
• CPC Class Codes: B41J 11/00216 using infrared [IR] radiation or microwaves
• CPC Class Codes: B41J 11/0022 using convection means, e.g. by using a fan for blowing or sucking air
• CPC Class Codes: B41J 11/0024 using conduction means, e.g. by using a heated platen
• CPC Class Codes: B41J 2/01 Ink jet
• CPC Class Codes: B41J 29/393 : Devices for controlling or analysing the entire machine ; Controlling or analysing mechanical parameters involving printing of test patterns
• 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: B41J 3/543 : with multiple inkjet print heads B41J2/17503, B41J2/2103 take precedence
• CPC Class Codes: H05K 1/185 : Components encapsulated in the insulating substrate of the printed circuit or incorporated in internal layers of a multilayer circuit semiconductor chips encapsulated by interconnect and support structures H01L23/5389, H01L24/00
• CPC Class Codes: H05K 3/125 : by ink-jet printing
• CPC Class Codes: H05K 3/4664 : Adding a circuit layer by thick film methods, e.g. printing techniques or by other techniques for making conductive patterns by using pastes, inks or powders H05K3/4647 takes precedence
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y10S 439/901 : Connector hood or shell
• CPC Class Codes: Y10T 29/49144 : by metal fusion

Abstract

A system for creating three dimensional products is provided. The system has a plurality of subsystems, with each subsystem configured to print one layer of N₁ of a plurality of layers making up a three dimensional product, where N₁ is greater than 1 and to change the layer being printed on receipt of a change instruction. In the event that one of the subsystems fails, the system configures at least one of the remaining subsystems to synchronously change to print the layer of the failed subsystem without requiring transfer of data relating the respective layer to the said at least one remaining subsystems. When a subsystem is changed to printing a different layer, the system is arranged to reconfigure the subsystem to be capable of printing N₂ of the plurality of layers, where N₁ and N₂ are the same number of layers.

Claims

1. A system for creating three dimensional products, the system comprising a plurality of subsystems, wherein:

each subsystem is configured to;

print one layer of N₁ of a plurality of layers making up a three dimensional product, where N₁ is greater than 1; and

to change the layer being printed on receipt of a change instruction;

in the event that one of the subsystems fails, at least one of the remaining subsystems is configured to synchronously change to print the layer of the failed subsystem without requiring transfer of data relating the respective layer to the said at least one remaining subsystems; and

when a subsystem changes to printing a different layer, the system is arranged to reconfigure the subsystem to be capable of printing N₂ of the plurality of layers, where N₁ and N₂ are the same number of layers.

2. The system of claim 1 wherein when a first subsystem changes to printing a different layer, another of the subsystems changes to printing the layer previously carried out by the first subsystem.

3. The system of claim 1 wherein the reconfiguration occurs by replacement of at least one component or by data transfer.

4. The system of claim 1 wherein each layer is defined by a data set and each subsystem stores a plurality of data sets, each relating to a different layer, and when printing a layer the subsystem accesses the corresponding data set.

5. The system of claim 4 wherein the layer being printed by a subsystem changes, the subsystem changes the data set being accessed.

6. The system of claim 4 wherein, in the event of a failure, data relating to a layer carried out by different subsystems is transferred to each of the subsystems that change the layer being printed, said data transfer occurring simultaneously or subsequent to the change of layer being printed.

7. The system of claim 4 wherein the subsystems are part of a pipelined system and wherein each subsystem stores data relating to at least the layers printed by its upstream subsystem.

8. The system of claim 4 wherein each subsystem is configured to store data relating to at least two other layers.

9. The system of claim 1, wherein the system prints at least part of each of multiple layers simultaneously.

10. The system of claim 1 including at least one spare subsystem.

11. A system as claimed in claim 1 comprising a plurality of printheads in each subsystem.

12. A system as claimed in claim 11 wherein the printheads are configured to enable printing of at least two different materials in at least one layer.

13. A system as claimed in claim 12 wherein the printheads are configured such that at least one of the layers may be printed with a first set of materials and at least one other of the layers may be printed with a second set of materials, and the first and second sets are not the same.

14. A system as claimed in claim 12 wherein the system is configured to enable at least one first printhead that is initially configured to print at least part of a first layer to be dynamically reconfigured to print at least part of a second layer.

15. A system as claimed in claim 14 wherein if at least one printhead initially configured to print the second layer fails whilst printing said second layer, said at least one first printhead is dynamically reconfigured to complete the printing of at least part of said second layer.