Method and apparatus for printing of three-dimensional objects

• US 20080166480A1
• Filed: 10/31/2007
• Published: 07/10/2008
• Est. Priority Date: 12/03/2002
• Status: Abandoned Application

• Current Assignee: Objet Geometries
• Original Assignee: Objet Geometries
• Inventors: Kritchman, Eliahu M., Gothait, Hanan, Napadensky, Eduardo
• Application Number:
  US11/980,742
• Publication Number:
  US 20080166480A1
• Time in Patent Office: Days
• US Class Current: 427/258
• CPC Class Codes: B29C 2948/92209 Temperature
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 37/005 Compensating volume or shape change during moulding, in general
• CPC Class Codes: B29C 41/02 for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 41/48 Compensating volume change, e.g. retraction
• CPC Class Codes: B29C 41/52 Measuring, controlling or regulating
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29L 2009/00 Layered products
• 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 40/10 Pre-treatment
• CPC Class Codes: B33Y 40/20 : Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: B41M 3/16 : Braille printing typewriters or selective printing mechanisms for Braille printing B41J3/32

Abstract

A method and apparatus to help control the quality of printed three-dimensional objects are provided. The method may include dispensing one or more building material to construct a support construction underneath surfaces of the three-dimensional object and dispensing at least one of the building materials to construct a thickening layer of building material of pre-determined thickness around at least part of the three-dimensional object.

Claims

1. A method of printing a three-dimensional object, the method comprising:

dispensing one or more building materials in consecutive layers to form a three-dimensional object;

dispensing at least one of said building materials to construct a support construction underneath surfaces of said three-dimensional object;

dispensing at least one of said building materials to construct a thickening layer of building material of predetermined thickness around at least part of said three-dimensional object.

2. The method of claim 1, wherein constructing the thickening layer serves to:

(a) shield the external surfaces of said three-dimensional object from disproportionate curing and/or uneven heating or cooling; and

/or

(b) prevent accumulation of excess building material on surfaces of the three-dimensional object; and

/or

(c) prevent or minimize deformation caused by thermal inconsistencies between inner and outer parts of the three-dimensional object; and

/or

(d) help even finished object surfaces; and

/or

(e) prevent knocking of a leveling device colliding with the three-dimensional object.

3. The method of claim 1, wherein said thickening layer comprises a modeling material, a support material or a combination thereof.

4. The method of claim 1, wherein said thickening layer is built around vertical walls of said three-dimensional object.

5. The method of claim 1, wherein said thickening layer is built around the external surfaces of the entire three-dimensional object that are not in contact with the support construction.

6. The method of claim 1, wherein said thickening layer is built around surfaces of the three-dimensional object.

7. The method of claim 1, comprising curing said three-dimensional object and/or said thickening layer.

8. The method of claim 1 further comprising:

removing said support construction and said thickening layer after printing is complete.

9. An apparatus for printing a three-dimensional object, the apparatus comprising:

a printing head to dispense one or more building materials; and

a controller to control formation of said three-dimensional object, one or more support constructions and a thickening layer of building material of a pre-determined thickness around at least part of said three-dimensional object.

10. The apparatus of claim 9 further comprising a curing unit to cure said three-dimensional object and/or thickening layer.

11. The apparatus of claim 9, wherein the building material of the thickening layer comprises a modeling material, a support material or a combination thereof.

12. The apparatus of claim 9, wherein said thickening layer is built

(a) to prevent accumulation of excess building material on surfaces of the object;

and/or

(b) to prevent or minimize deformation caused by thermal inconsistencies between inner and outer parts of the three-dimensional object; and

/or

(c) to help even finished object surfaces; and

/or

(d) to shield the external surfaces of said three-dimensional object from disproportionate curing and/or uneven heating or cooling.

13. The apparatus of claim 9, further comprising a leveling device and wherein said thickening layer is built to prevent knocking of the leveling device colliding with the three-dimensional object.

14. The apparatus of claim 9, wherein said thickening layer is built around vertical walls of said three-dimensional object.

15. The apparatus of claim 9, wherein said thickening layer is built around the external surfaces of the entire three-dimensional object that are not in contact with said support construction.

16. The apparatus of claim 9, wherein said thickening layer is built around surfaces of the three-dimensional object.