Apparatus and methods for removing printed articles from a 3-D printer

• US 20070126157A1
• Filed: 11/30/2006
• Published: 06/07/2007
• Est. Priority Date: 12/02/2005
• Status: Abandoned Application

• Current Assignee: Z CORPORATION (A Holdings Corp.)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Bredt, James
• Application Number:
  US11/606,960
• Publication Number:
  US 20070126157A1
• Time in Patent Office: Days
• US Class Current: 264/334
• 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 64/165 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: B29C 64/35 Cleaning
• 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 40/20 Post-treatment, e.g. curing, coating or polishing

Abstract

The invention relates to methods and apparatus for removing finished articles from a powder-based rapid prototyping system. In particular, the invention relates to extracting a printed article from a powder bed in a build chamber of a three-dimensional printer by using a mechanism adapted for displacing the article by at least one of pushing the article at least partially out of the powder bed, pulling the article at least partially out of the powder bed, or changing a boundary of the build chamber to move at least a portion of the unbound powder away from the article.

Claims

1. An apparatus for extracting an article from a powder bed in a build chamber of a three-dimensional printer, the apparatus comprising:

a mechanism adapted for use with the three-dimensional printer and disposed at least partially within the build chamber and adapted for displacing the article comprising bound powder from the powder bed comprising unbound powder by at least one of;

pushing the article at least partially out of the powder bed;

pulling the article at least partially out of the powder bed; and

changing a boundary of the build chamber to move at least a portion of the unbound powder away from the article.

2. The apparatus of claim 1, wherein the pushing mechanism comprises at least one of a pin, a basket, a grate, a spoon, and a cradle.

3. The apparatus of claim 1, wherein the pulling mechanism comprises at least one of a sling, a basket, a net, a spoon, and a hook.

4. The apparatus of claim 1, wherein the boundary changing mechanism comprises at least a portion of a wall defining the powder bed.

5. The apparatus of claim 1, further comprising at least one of a flow inducer and a vibrator to fluidize at least a portion of the powder bed.

6. The apparatus of claim 1, further comprising a mechanism for imparting reciprocating motion to the article within the powder bed.

7. A method of extracting an article from a powder bed in a build chamber of a three-dimensional printer, the method comprising the steps of:

displacing the article comprising bound powder from the powder bed comprising unbound powder by employing a mechanism adapted for use with the three-dimensional printer and disposed at least partially within the build chamber by at least one of;

push the article at least partially out of the powder bed;

pull the article at least partially out of the powder bed; and

change a boundary of the build chamber to move at least a portion of the unbound powder away from the article; and

removing the article from the three-dimensional printer.

8. The method of claim 7, wherein the push mechanism comprises at least one of a pin, a basket, a grate, a spoon, and a cradle.

9. The method of claim 7, wherein the pull mechanism comprises at least one of a sling, a basket, a net, a spoon, and a hook.

10. The method of claim 7, wherein the boundary change mechanism comprises at least a portion of a wall defining the powder bed.

11. The method of claim 7, further comprising the step of employing at least one of fluidic flow and vibration to fluidize at least a portion of the powder bed while displacing the article.

12. The method of claim 7, further comprising the step of imparting a reciprocating motion to the article within the powder bed.

13. An apparatus for removing a printed article from a three-dimensional printer, the apparatus comprising:

a build chamber disposed within the three-dimensional printer;

a moveable build surface disposed within the build chamber and adapted for receiving unbound powder, portions of layers of the unbound powder being bonded through the action of the three-dimensional printer to produce the printed article; and

an ejection mechanism disposed through at least one of the build surface and a wall of the build chamber,

wherein, the ejection mechanism is adapted for movement relative to at least one of the build surface and the wall of the build chamber.

14. The apparatus of claim 13, wherein the ejection mechanism comprises a ratchet mechanism for causing the movement of the ejection mechanism relative to at least one of the build surface and the wall of the build chamber.

15. The apparatus of claim 13, wherein the ejection mechanism comprises at least one porous surface.

16. An apparatus for removing a printed article from a three-dimensional printer, the apparatus comprising:

a build chamber at least partially disposed within the three-dimensional printer and comprising a moveable build surface and at least one moveable wall, wherein the build chamber is adapted for receiving unbound powder for producing the printed article; and

wherein the at least one moveable wall is separable from the build surface to allow unused powder to exit the chamber.

17. The apparatus of claim 16, wherein the at least one moveable wall is pivotably mounted to the apparatus.

18. The apparatus of claim 16, further comprising a collection chamber disposed below the build surface for receiving the powder exiting from the build chamber.

19. A method for extracting a printed article from a three-dimensional printer, the method comprising:

supporting the printed article within a build chamber with an ejection mechanism, wherein the build chamber is adapted for receiving unbound powder, portions of layers of the unbound powder being bonded through the action of the three-dimensional printer to produce the printed article, and wherein the ejection mechanism is disposed through a build surface located within the build chamber; and

moving at least one of the ejection mechanism and the build surface relative to the other to separate the printed article from unbound powder in the build chamber during the printing process.

20. The method of claim 19, further comprising the step of advancing the ejection mechanism relative to the build surface to advance the printed article beyond a boundary of the build chamber.