INSERTING INHIBITOR TO CREATE PART BOUNDARY ISOLATION DURING 3D PRINTING

• US 20140271961A1
• Filed: 03/12/2014
• Published: 09/18/2014
• Est. Priority Date: 03/12/2013
• Status: Active Grant

• Current Assignee: University of Southern California
• Original Assignee: University of Southern California
• Inventors: Khoshnevis, Behrokh
• Granted Patent: US 9,403,725 B2
• Time in Patent Office: Days
• US Class Current: 425/78
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2003/1032 comprising a grain growth inhibitor
• CPC Class Codes: B22F 2003/1054 by microwave
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• 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 64/165 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: B29L 2023/00 Tubular articles B29L2024/00 takes precedence ; catheters B29L2031/7542
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: C04B 2235/6026 Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 33/04 Clay; Kaolin
• CPC Class Codes: C04B 33/24 Manufacture of porcelain or white ware
• CPC Class Codes: C04B 35/48 based on zirconium or hafnium oxides, zirconates, zircon or hafnates
• CPC Class Codes: C04B 35/622 Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• CPC Class Codes: C04B 35/62218 obtaining ceramic films, e.g. by using temporary supports
• CPC Class Codes: C04B 35/6303 Inorganic additives
• CPC Class Codes: C04B 35/634 Polymers C04B35/636 takes precedence
• CPC Class Codes: C04B 35/63452 Polyepoxides
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A 3D printing system may print a desired 3D object. A fusible powder may fuse when subjected to a fusing condition. A deposition system may deposit portions of the fusible powder on a substrate. A fusing system may apply the fusing condition to the deposited fusible powder. Inhibitor material may not fuse when subjected to the fusing condition. An insertion system may insert a portion of the inhibitor material between portions of the deposited fusible powder after having been deposited by the deposition system, but before being fused by the fusing system, so as to form a boundary that defines at least a portion of a surface of the desired 3D object.

Claims

1. A 3D printing system for printing a desired 3D object comprising:

a fusible powder that fuses when subjected to a fusing condition;

a deposition system that deposits portions of the fusible powder on a substrate;

a fusing system that applies the fusing condition to the deposited fusible powder;

inhibitor material that does not fuse when subjected to the fusing condition; and

an insertion system that inserts a portion of the inhibitor material between portions of the deposited fusible powder after having been deposited by the deposition system but before being fused by the fusing system so as to form a boundary that defines at least a portion of a surface of the desired 3D object.

2. The 3D printing system of claim 1 wherein:

the insertion system includes a nozzle that has an interior passageway through which the inhibitor material travels;

the nozzle has a lower end that includes;

a leading edge in the shape of a plow that can plow a trough between portions of the fusible powder when the lower end of the nozzle traverses such portions; and

a rearward-facing opening though which inhibitor material can be ejected from the nozzle and into the trough immediately after the trough is plowed by the leading edge, thereby filling the trough as the trough is plowed; and

the insertion system causes;

the leading edge to plow through portions of the unfused fusible powder; and

the opening to eject inhibitor material from the nozzle immediately after the trough is plowed by the leading edge, thereby filling the trough as the trough is plowed.

3. The 3D printing system of claim 2 wherein the inhibitor material is a powder.

4. The 3D printing system of claim 3 wherein the insertion system includes a vibrating element that controls the flow of the inhibitor powder.

5. The 3D printing system of claim 2 wherein the inhibitor material is a liquid.

6. The 3D printing system of claim 2 wherein the insertion system only uses the force of gravity to cause the inhibitor material to travel through the passageway and to be ejected into the trough.

7. The 3D printing system of claim 2 wherein the insertion system includes rotary axis actuator that controllably rotates the leading edge of the nozzle so as cause the leading edge to always be leading the direction of the nozzle movement.

8. The 3D printing system of claim 2 wherein:

the deposition system deposits the fusible powder in stacked layers; and

the insertion system inserts the inhibitor material between the portions of the fusible powder in each stacked layer after the deposition system deposits the stacked layer into which the inhibitor material is inserted and before the deposition system deposits the next stacked layer.

9. The 3D printing system of claim 2 wherein the insertion system inserts the inhibitor material while the lower end of the nozzle is moving horizontally and while the lower end of the nozzle is moving vertically.

10. The 3D printing system of claim 9 wherein the insertion system inserts the inhibitor material between portions of multiple layers of fusible powder, beginning to do so after all of the multiple layers have been deposited by the 3D printer.

11. The 3D printing system of claim 10 further comprising guy wires attached to the nozzle that prevent the nozzle from bending while the inhibitor material is being inserted.

12. The 3D printing system of claim 2 wherein the insertion system includes a six-axis gantry control system that separately controls six axes of nozzle movement.

13. The 3D printing system of claim 2 wherein the rearward-facing opening has an adjustable height.

14. The 3D printing system of claim 13 wherein the height of the rearward-facing opening is controlled by a movable gate.

15. The 3D printing system of claim 1 wherein the fusing condition is sintering.

16. The 3D printing system of claim 15 wherein the fusible powder includes metallic powder.

17. The 3D printing system of claim 15 wherein the inhibitor material is a powdered ceramic.

18. The 3D printing system of claim 17 wherein the inhibitor material includes magnesium oxide or ilmenite.

19. The 3D printing system of claim 1 wherein the fusible condition is exposure to a liquid.

20. The 3D printing system of claim 19 wherein the fusible material and the liquid each include complementary component parts of an epoxy.