APPARATUS AND METHODS FOR HANDLING MATERIALS IN A 3-D PRINTER

• US 20110233808A1
• Filed: 06/07/2011
• Published: 09/29/2011
• Est. Priority Date: 05/26/2006
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Davidson, Thomas
• Granted Patent: US 8,185,229 B2
• Time in Patent Office: Days
• US Class Current: 264/71
• 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

1-9. -9. (canceled)

10. A build chamber for use in a three-dimensional printer and adapted for receiving powder for producing three-dimensional objects, the chamber comprising:

a build surface for receiving the powder, the build surface comprising;

a first plate defining a plurality of spaced holes having a pitch; and

a second plate defining a plurality of openings spaced apart and offset from the plurality of holes in the first plate, the second plate disposed below and spaced from the first plate, and

a mechanism for vibrating the build surface,

wherein the pitch corresponds to the space between proximate edges of adjacent holes.

11. A build chamber for use in a three-dimensional printer and adapted for receiving powder for producing three-dimensional objects, the chamber comprising:

a build surface for receiving the powder, the build surface comprising;

a first plate defining a plurality of spaced holes having a pitch; and

a second plate defining a plurality of openings spaced apart and offset from the plurality of holes in the first plate, the second plate disposed below and spaced from the first plate,

wherein the pitch corresponds to the space between proximate edges of adjacent holes, and the space between the plates is variable.

12. A method of controlling the flow of unbound powder in a build chamber, the method comprising the steps of:

providing a build surface for receiving the powder, the build surface comprising;

a first plate defining a plurality of spaced apart holes having a pitch; and

a second plate defining a plurality of openings spaced apart and offset from the plurality of holes in the first plate, the second plate disposed below and spaced from the first plate, wherein the pitch corresponds to the space between proximate edges of adjacent holes; and

providing a vacuum source below the build surface.

13. The method of claim 12 further comprising the step of maintaining ambient pressure within the build chamber to prevent flow of powder through the build surface.

14. The method of claim 12 further comprising the step of activating the vacuum source to create a vacuum beneath the build surface to cause the powder to flow through the first and second plates.

15. The method of claim 12, wherein the build chamber comprises a plenum disposed below the build surface for coupling the vacuum source to the build chamber.

16. The method of claim 15, wherein the plenum comprises an outlet for removing unbound powder from the build chamber when the vacuum source is activated.

17. The method of claim 12, wherein the build chamber comprises:

at least one wall at least partially circumscribing the build surface and at least partially defining the chamber; and

a piston disposed below the build surface and adapted to the build chamber to move the build surface vertically relative to the at least one wall.

18. The method of claim 14 further comprising the step of vibrating the build surface to promote flow of unbound powder.

19. The method of claim 12 further comprising the step of varying the space between the first plate and the second plate to accommodate powders having different angles of repose.

20. The method of claim 12, wherein at least one of the first plate and the second plate are interchangeable with plates adapted for differing angles of repose.

21. The method of claim 12, wherein the plurality of openings of the second plate are offset from the plurality of holes in the first plate by approximately 50% of the pitch.

22. The method of claim 12, wherein the pitch is at least equal to 2(space between the plates)(cotangent of an angle of repose of the powder)+(diameter of holes).

23. The method of claim 12, wherein the pitch is approximately equal to 2(space between the plates)(cotangent of an angle of repose of the powder)+(diameter of holes).