Apparatus for three dimensional printing using imaged layers
First Claim
1. A method of building an object from a plurality of cross sectional layers with a three-dimensional printer (3DP), the method comprising:
- sintering at least one first layer of sinterable powder with a first energy density level;
partially sintering at least one second layer of sinterable powder with a second energy density level less than the first energy density level; and
sintering at least one third layer of sinterable powder with a third energy density level greater than the second energy density level to form one or more of the plurality of cross sectional layers.
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Accused Products
Abstract
A three-dimensional printer adapted to construct three dimensional objects is disclosed. In an exemplary embodiment, the printer includes a first surface adapted to receive a bulk layer of sinterable powder, a polymer such as nylon powder; a radiant energy source, e.g., an incoherent heat source adapted to focus the heat energy to sinter an image from the layer of sinterable powder; and a transfer mechanism adapted to transfer or print the sintered image from the first surface to the object being assembled while fusing the sintered image to the object being assembled. The transfer mechanism is preferably adapted to simultaneously deposit and fuse the sintered image to the object being assembled. The process of generating an image and transferring it to the object being assembled is repeated for each cross section until the assembled object is completed.
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Citations
17 Claims
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1. A method of building an object from a plurality of cross sectional layers with a three-dimensional printer (3DP), the method comprising:
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sintering at least one first layer of sinterable powder with a first energy density level;
partially sintering at least one second layer of sinterable powder with a second energy density level less than the first energy density level; and
sintering at least one third layer of sinterable powder with a third energy density level greater than the second energy density level to form one or more of the plurality of cross sectional layers. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of generating an object from a plurality of cross sections with a three-dimensional printer (3DP), the method comprising:
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generating a plurality of images, each image being sintered from a portion of a bulk layer of sinterable powder on a first surface;
stacking a first set of the plurality of images to form a substantially rigid support;
stacking a second set of the plurality of images on the rigid support to form the object; and
removing unsintered powder after sintering one or more of the plurality of bulk layers and before stacking a next one of the plurality of images. - View Dependent Claims (9, 10, 11, 12)
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13. A three-dimensional printer (3DP) adapted to generate an object assembled from a plurality of cross sections, comprising:
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a first surface configured to receive a bulk layer of sinterable powder;
a focused radiant energy source configured to selectively fuse a portion of the layer of sinterable powder on the first surface into a sintered image, the sintered image corresponding to one of said cross sections;
a transfer mechanism adapted to transfer the sintered image from the first surface to the object being assembled; and
a controller configured to transfer one or more sintered images to generate;
a) a support structure comprising a substantially rigid portion; and
b) the object on the rigid portion. - View Dependent Claims (14, 15, 16)
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17. A method of building an object from a plurality of cross sectional layers with a three-dimensional printer (3DP), the method comprising:
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generating a rigid support from a first set of one or more sintered images formed from sinterable powder;
generating an interface from a second set of one or more layers of unsintered power transferred to the rigid support; and
generating the object from a third set of one or more sintered images formed from sinterable powder.
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Specification