Apparatus and Methods for 3D Printing

• US 20080042321A1
• Filed: 09/24/2007
• Published: 02/21/2008
• Est. Priority Date: 05/23/2003
• Status: Abandoned Application

• Current Assignee: Z CORPORATION (A Holdings Corp.)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Russell, David, Kingsley, Joshua, Hernandez, Andres, Berlin, Andrew
• Application Number:
  US11/860,087
• Publication Number:
  US 20080042321A1
• Time in Patent Office: Days
• US Class Current: 264/308
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• 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 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: B41J 2/16532 by applying vacuum only
• CPC Class Codes: B41J 2/16535 using wiping constructions B41J2/16552 takes precedence
• CPC Class Codes: B41J 2/16552 using cleaning fluids
• CPC Class Codes: B41J 2/16579 Detection means therefor, e.g. for nozzle clogging
• CPC Class Codes: B41J 29/17 Cleaning arrangements
• 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

Abstract

The invention relates to apparatus and methods for producing three-dimensional objects and auxiliary systems used in conjunction with the aforementioned apparatus and methods. The apparatus and methods involve continuously printing radially about a circular and/or rotating build table using multiple printheads. The apparatus and methods also include optionally using multiple build tables. The auxiliary systems relate to build material supply, printhead cleaning, diagnostics, and monitoring operation of the apparatus.

Claims

1-26. -26. (canceled)

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

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

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

28. The method of claim 27 further comprising the step of rotating the build table continuously.

29. The method of claim 27, wherein the step of depositing successive layers of a build material on a rotary build table includes distributing the build material over at least a portion of the build table with a spreader.

30. The method of claim 27 further comprising the step of measuring an amount of excess build material deposited on the rotary build table.

31. The method of claim 30 further comprising the step of adjusting the amount of build material deposited on the rotary build table based on the amount of excess build material measured.

32. The method of claim 27, wherein the step of depositing a liquid is performed by an array of at least one printhead.

33. The method of claim 32, wherein the array is configured to dispense fluid at substantially any radial location of the rotary build table without adjustment.

34. The method of claim 32, wherein the array prints an entire surface of the build table by continuous consecutive radial scanning motions.

35. The method of claim 32, wherein the array of printheads can be adjusted incrementally radially relative to the rotary build table.

36-42. -42. (canceled)

43. An apparatus for cleaning a printhead used in a three-dimensional printer, the apparatus comprising:

a base;

a cam track disposed within the base;

a cap carrier slidably engaged with the cam track; and

a sealing cap defining a cavity and disposed on the carrier, the cap being transportable into engagement with a face of the printhead by the carrier.

44. The apparatus of claim 43 further comprising:

a cleaning fluid source in communication with the cap for cleaning the printhead face; and

a vacuum source in communication with the cap for removing used wash fluid and debris.

45. The apparatus of claim 44, wherein the vacuum source creates a negative pressure within the cavity, the negative pressure preventing the wash fluid from entering a jet nozzle and drawing at least one of a binder fluid and debris from the jet nozzle.

46. The apparatus of claim 43 further comprising a spring coupled to the carrier and the base to bias the carrier into a receiving position for receiving the printhead.

47. The apparatus of claim 46, wherein the carrier includes a stop disposed on a distal end of the carrier for engaging the printhead as the printhead enters the apparatus and the printhead slides the carrier rearward along the cam track after engaging the stop until the printhead face and cap sealably engage.

48. The apparatus of claim 47 further comprising a latch pawl coupled to the base for engaging with the carrier to prevent forward movement of the carrier.

49. The apparatus of claim 48 further comprising a squeegee disposed on a proximal end of the carrier, the squeegee positioned to engage the printhead face as the printhead exits the apparatus.

50. A method of cleaning a printhead used in a three-dimensional printer comprising the steps of:

receiving the printhead within an apparatus comprising;

a base;

a cam track disposed within the base;

a cap carrier slidably engaged with the cam track; and

a sealing cap defining a cavity and disposed on the carrier;

engaging a face of the printhead with the cap;

drawing a vacuum on the cavity; and

introducing a cleaning fluid into the cavity and into contact with the printhead face.

51. The method of claim 50 further comprising the step of removing the cleaning fluid from the cavity.

52. The method of claim 51 further comprising the steps of:

disengaging the cap from the printhead face; and

wiping the printhead face with a squeegee as the printhead is withdrawn from the apparatus.

53. The method of claim 50, wherein the vacuum source creates a negative pressure within the cavity, the negative pressure preventing the wash fluid from entering a jet nozzle and drawing at least one of a binder fluid and debris from the jet nozzle.