Printer system for developing a three-dimensional structure

• US 20070030326A1
• Filed: 10/11/2006
• Published: 02/08/2007
• 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 7,322,674 B2
• Time in Patent Office: Days
• US Class Current: 347/107
• 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 printer system for developing a three dimensional, printed structure includes a plurality of printheads arranged in groups, the printheads in each group being configured to print voxels of material to define a respective layer of the structure. A substrate is configured to be operatively displaced with respect to each group so that printed voxels from each successive group can form successive layers of the structure upon the substrate.

Claims

1. A printer system for developing a three dimensional, printed structure, the system comprising:

a plurality of printheads arranged in groups, the printheads in each group being configured to print voxels of material to define a respective layer of the structure; and

a substrate configured to be operatively displaced with respect to each group so that printed voxels from each successive group can form successive layers of the structure upon the substrate.

2. A printer system as claimed in claim 1, wherein each printhead is configured to print a row of voxels such that the voxels are in a close pack hexagonal pattern.

3. A printer system as claimed in claim 1, wherein each printhead is configured to print one of a polymeric material, a metal, a sacrificial material, and an evaporative drying material.

4. A printer system as claimed in claim 3, wherein at least one printhead is configured to print one of Indium and an alloy of Indium and Gallium, to define the metal.

5. A printer system as claimed in claim 3, wherein at least one printhead is configured to print a polymeric material with a melting point in the range of about 120°

C. to 180°

C.

6. A printer system as claimed in claim 3, wherein at least one printhead is configured to print a wax having a melting point of above 80°

C., to define the sacrificial material.

7. A printer system as claimed in claim 1, wherein the groups are arranged consecutively along a direction of movement of the substrate, with each successive group positioned further from the substrate than a preceding group.

8. A printer system as claimed in claim 1, in which each printhead includes two rows of nozzles, each printhead being configured so that one of the rows prints oddly numbered voxels while the other row prints evenly numbered voxels.