Apparatus and methods for handling materials in a 3-D printer

• US 20080047628A1
• Filed: 05/25/2007
• Published: 02/28/2008
• Est. Priority Date: 05/26/2006
• Status: Abandoned Application

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Torres, Diego, Davidson, Thomas, Kinsley, Joshua
• Application Number:
  US11/807,325
• Publication Number:
  US 20080047628A1
• Time in Patent Office: Days
• US Class Current: 141/18
• CPC Class Codes: B29C 31/02 Dispensing from vessels, e.g. hoppers into a mould cavity B29C31/04; large containers characterised by discharge means B65D88/28, B65D88/54
• 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 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• 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 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: Y10T 137/86187 Plural tanks or compartments connected for serial flow

Abstract

The present invention is directed towards methods and apparatus for handling powder in a 3D printer. The invention includes a means of transporting powder from multiple sources to a powder dispensing apparatus with minimal user intervention, thus reducing contamination of the 3D printer and surrounding area with loose powder, while also providing a means of improving the recycling of powder for re-use.

Claims

1. A powder handling system for a three-dimensional printer, the system comprising:

a plurality of powder holding receptacles; and

a vacuum source coupled to the plurality of powder holding receptacles, wherein the vacuum source transfers powder between the powder holding receptacles.

2. The system of claim 1 further comprising a multiport valve in fluidic communication with the plurality of powder holding receptacles and the vacuum source, wherein the vacuum source transfers powder between the powder holding receptacles through the valve.

3. The system of claim 1, further comprising an external powder source, the external powder source adapted to be coupled to the vacuum source.

4. The system of claim 1, wherein the powder holding receptacles are selected from the group consisting of a build chamber, a work space volume, a dispensing hopper, a depowdering chamber, and at least one overflow cavity.

5. The system of claim 1 further comprising a filtration system disposed between the vacuum source and the plurality of powder holding receptacles.

6. A three-dimensional printer comprising:

a powder dispensing hopper;

a build chamber for receiving powder;

at least one printhead for selectively applying binder to a layer of powder in the build chamber; and

a vacuum source coupled to the dispensing hopper and the build chamber, wherein the vacuum source transfers powder between the dispensing hopper and the build chamber.

7. The printer of claim 6 further comprising a multiport valve in fluidic communication with the dispensing hopper, the build chamber, and the vacuum source, wherein the vacuum source transfers powder between the dispensing hopper and the build chamber through the valve.

8. The printer of claim 7, further comprising at least one overflow cavity coupled to the vacuum source, wherein the vacuum source transfers powder from the at least one overflow cavity through the valve.

9. A method of providing powder to a three-dimensional printer from multiple sources, the method comprising the steps of:

providing a plurality of powder holding receptacles, the plurality of powder holding receptacles including at least one powder dispensing hopper adapted to be coupled to the three-dimensional printer;

coupling the plurality of powder holding receptacles to a vacuum source; and

transferring powder between the powder holding receptacles with the vacuum source.

10. The method of claim 9 further comprising the step of providing a multiport valve between the vacuum source and the plurality of powder holding receptacles for selectively connecting the vacuum source to the powder holding receptacles.

11. The method of claim 10 further comprising the step of actuating the valve to selectively transfer powder to the powder dispensing hopper from one of the plurality of powder holding receptacles.

12. The method of claim 9 further comprising the step of providing a filtration system between the vacuum source and the plurality of powder holding receptacles.

13. A multiport valve for use in a powder transfer system of a three-dimensional printer, the valve comprising:

a first portion defining a port radially disposed a fixed distance from a central point; and

a second portion coupled to the first portion at the central point, the second portion rotatable relative to the first portion and defining a plurality of ports, the plurality of ports radially disposed about the central point from the fixed distance so that each port is alignable with the port in the first portion when the second portion is rotated to a set position, thereby enabling flow therebetween.

14. The valve of claim 13, wherein the second portion can be rotated relative to the first portion by a motor and gear assembly.

15. The valve of claim 13, wherein the second portion can be automatically rotated relative to the first portion in response to a signal.

16. The valve of claim 13 further comprising at least one stop to limit rotational travel of the second portion relative to the first portion.

17. The valve of claim 13 further comprising a seal disposed between the first portion and the second portion, wherein the first portion and the second portion are biased into contact with the seal disposed therebetween.

18. An electrical connection system for printheads in a three-dimensional printer, the connection system comprising:

a base plate for connecting the system to a signal source, the base plate comprising a plurality of solder pads disposed in a set pattern;

a connector mounted to the base plate and adapted for providing a signal to a printhead, the connector defining a plurality of stepped through holes oriented in the connector to correspond with the solder pads; and

a plurality of pogo pins selectively disposed within the stepped through holes of the connector, the pogo pins supplying signals to the printheads.

19. The system of claim 18, wherein the signal can provide at least one of power and instructions to the printhead.

20. The system of claim 18 further comprising a seal disposed between the connector and the base plate to prevent ingress of contamination.