LAYER TRANSFUSION WITH HEAT CAPACITOR BELT FOR ADDITIVE MANUFACTURING

• US 20130186558A1
• Filed: 03/08/2013
• Published: 07/25/2013
• Est. Priority Date: 09/23/2011
• Status: Abandoned Application

• Current Assignee: Evolve Additive Solutions, Inc.
• Original Assignee: Stratasys Incorporated
• Inventors: Comb, James W., Chillscyzn, Steven A., Hanson, William J., Sanders, J. Randolph, Bacus, Michael W.
• Application Number:
  US13/790,406
• Publication Number:
  US 20130186558A1
• Time in Patent Office: Days
• US Class Current: 156/277
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• 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: G03G 15/1625 on a base other than paper
• CPC Class Codes: G03G 15/169 with means for preconditioning the toner image before the transfer G03G15/095 and G03G15/11 take precedence
• CPC Class Codes: G03G 15/2021 Plurality of separate fixing and/or cooling areas or units, two step fixing
• CPC Class Codes: G03G 15/224 Machines for forming tactile or three dimensional images by electrographic means, e.g. braille, 3d printing
• CPC Class Codes: G03G 15/24 whereby at least two steps are performed simultaneously
• CPC Class Codes: G03G 2215/1695 at the second or higher order transfer point

Abstract

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

Claims

1. An additive manufacturing system for printing a three-dimensional part, the additive manufacturing system comprising:

an imaging engine configured to develop an imaged layer;

a movable build platform;

a rotatable belt configured to receive the imaged layer from the imaging engine, wherein the rotatable belt has an average thermal inertia of at least about 400 joules/(meter²-Kelvin-second^0.5);

a first heater configured to heat the rotatable belt and the imaged layer on the rotatable belt;

a nip roller configured to press the heated imaged layer conveyed by the rotatable belt onto a top layer of the three-dimensional part retained by the movable build platform; and

a release roller configured to separate the pressed imaged layer from the heated rotatable belt such that the pressed imaged layer remains adhered as a new top layer of the three-dimensional part;

wherein the rotatable belt is configured to thermally conduct heat into the three-dimensional part while the pressed imaged layer moves between the nip roller and the release roller.

2. The additive manufacturing system of claim 1, wherein the first heater comprises a non-contact radiant heater.

3. The additive manufacturing system of claim 1, and further comprising a second heater configured to post-heat the three-dimensional part having the new top layer.

4. The additive manufacturing system of claim 1, wherein the nip roller is configured to be heated.

5. The additive manufacturing system of claim 1, wherein the moveable build platform is configured to move in a reciprocating rectangular pattern that is synchronized with a rotation of the rotatable belt.

6. The additive manufacturing system of claim 1, and further comprising a cooling unit configured to cool the three-dimensional part having the new top layer.

7. The additive manufacturing system of claim 6, wherein the cooling unit comprises a belt configured to be cooled down and to contact the new top layer of the three-dimensional part to conductively draw heat from the three-dimensional part.

8. The additive manufacturing system of claim 1, wherein the rotatable belt comprises a multiple-layer belt.

9. The additive manufacturing system of claim 1, wherein thermoplastic-based powder comprises an acrylonitrile-butadiene-styrene copolymer, and wherein the wherein the first heater is configured to heat the rotatable belt and the imaged layer on the rotatable belt to a temperature ranging from about 180°

C. to about 220°

C.

10. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:

imaging a layer of the three-dimensional part;

transferring the imaged layer to a rotatable belt having an average thermal inertia of at least about 400 joules/(meter²-Kelvin-second^0.5)

heating the rotatable belt and the imaged layer while the imaged layer is retained on the rotating belt;

pressing the heated imaged layer between the heated rotatable belt and a top surface of the three-dimensional part so that the heated imaged layer fuses to the top surface of the three-dimensional part;

maintaining contact between the rotatable belt and the fused imaged layer so as to conduct thermal energy from the heated rotatable belt to the three-dimensional part; and

releasing the pressed layer from the rotatable belt such that the pressed layer defines a new top surface of the three-dimensional part.

11. The method of claim 10, wherein imaging the layer comprises developing the layer with an electrophotography engine.

12. The method of claim 10, wherein pressing the heated layer between the rotatable belt and the top surface of the three-dimensional part comprises engaging the rotatable belt with a nip roller.

13. The method of claim 10, and further comprising cooling the three-dimensional part having the new top layer.

14. The method of claim 13, wherein cooling the three-dimensional part comprises drawing thermal energy from the three-dimensional part having the new top layer by thermal conduction.

15. The method of claim 14, wherein cooling by thermal conduction comprises contacting the new top layer with a cooling belt.

16. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:

imaging a layer of the three-dimensional part;

rotating a belt having an average thermal inertia of at least about 400 joules/(meter²-Kelvin-second^0.5);

transferring the imaged layer to the rotating belt;

heating the rotating belt and the imaged layer while the imaged layer is retained on the rotating belt;

engaging the heated rotatable belt with a nip roller, which presses the heated layer to a top surface of the three-dimensional part;

moving the three-dimensional part in a direction and at a rate that is synchronized with a rotation of the belt;

conducting thermal energy from the rotating belt to the three-dimensional part while moving the three-dimensional part in the synchronized direction and rate; and

releasing the pressed layer from the rotatable belt such that the pressed layer defines a new top surface of the three-dimensional part.

17. The method of claim 16, wherein imaging the layer comprises developing the layer with an electrophotography engine.

18. The method of claim 16, and further comprising cooling the three-dimensional part having the new top layer.

19. The method of claim 18, wherein cooling the three-dimensional part comprises drawing thermal energy from the three-dimensional part having the new top layer by thermal conduction.

20. The method of claim 16, heating the rotating belt and the imaged layer comprises heating the rotating belt and the imaged layer to a temperature ranging from about 180°

C. to about 220°

C.