THREE DIMENSIONAL PRINTING SYSTEM WITH IMPROVED MACHINE ARCHITECTURE

• US 20180345595A1
• Filed: 06/02/2017
• Published: 12/06/2018
• Est. Priority Date: 06/02/2017
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Tanner, Christopher
• Granted Patent: US 10,639,880 B2
• Time in Patent Office: Days
• 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 64/223 Foils or films, e.g. for transferring layers of building material from one working station to another
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• 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 50/02 for controlling or regulating additive manufacturing processes

Abstract

A three dimensional printing system includes a vertical support, a support plate, a resin vessel, a carriage, and a support fixture. The support plate has a proximal end affixed to the vertical support and extends along a first lateral axis to a distal end. The resin vessel is supported by the support plate and has a rear side that is proximate to the proximal end of the support plate. The resin fluid outlet is supported over the rear side of the resin vessel. The carriage is configured to be translated vertically along the vertical support. A pair of fixture receiving arms extend from the carriage along the first lateral axis from a proximal to a distal end. The fixture receiving arms are spaced apart along a second lateral axis that is perpendicular to the first lateral axis. The support fixture is supported by the two fixture receiving arms.

Claims

1. A three dimensional printing system for fabricating a three dimensional article of manufacture comprising:

a vertical support;

a support plate affixed to the vertical support and extending therefrom along a first lateral axis from a proximal end to a distal end;

a resin vessel supported by the support plate, the resin vessel having a rear side proximate to the proximal end of the support plate;

a resin fluid outlet that is supported over the rear side of the resin vessel;

a carriage configured to be translated vertically along the vertical support;

a pair of fixture receiving arms that extend from the carriage along the first lateral axis from a proximal to a distal end, the fixture receiving arms spaced apart along a second lateral axis that is perpendicular to the first lateral axis; and

a support fixture supported by and extending between the two fixture receiving arms.

2. The three dimensional printing system of claim 1 wherein the resin fluid outlet is supported by a resin handling module having a first module arm supporting and positioning the fluid outlet over the rear side of the resin vessel.

3. The three dimensional printing system of claim 2 further comprising a fluid level sensor and wherein the resin handling module includes a second module arm supporting the fluid level sensor over the rear side of the resin vessel and wherein the first module arm and the second module arm are spaced apart along the second lateral axis.

4. The three dimensional printing system of claim 3 wherein the resin module arms are positioned between the fixture receiving arms with respect to the second lateral axis.

5. The three dimensional printing system of claim 1 wherein the resin vessel includes:

a vessel body having an inner edge defining a central opening; and

a transparent sheet that closes the central opening to define a lower bound for a body of resin to be contained in the resin vessel.

6. The three dimensional printing system of claim 5 wherein the vessel body has an upper surface defining a channel having a receiving end proximate to the rear side of the resin vessel and extending along the first lateral axis to allow fluid flow to the central opening, the fluid outlet is positioned over the receiving end of the channel.

7. The three dimensional printing system of claim 5 wherein the vessel body has two lateral sides each extending along the first lateral axis each having a latch feature and further comprising two latches that are configured to engage the latch features to secure the resin vessel to the support plate.

8. The three dimensional printing system of claim 5 wherein the support fixture includes:

a lower planar portion having a lower surface upon which the three dimensional article of manufacture is formed;

a side wall extending upwardly from the lower planar portion; and

a pair of upper portions extending outwardly in two directions from the side wall and supported by the two fixture receiving arms.

9. The three dimensional printing system of claim 8 wherein a pair of pins extended upwardly from the fixture receiving arms, the pair of upper portions define two datum features that receive the pair of pins when the support fixture is loaded onto the fixture receiving arms.

10. The three dimensional printing system of claim 8 wherein the pair of upper portions are formed from a magnetic material, the fixture receiving arms include magnets that hold the upper portions onto the fixture receiving arms.

11. The three dimensional printing system of claim 1 further comprising a fluid spill containment vessel mounted to a lower side of the support plate.

12. The three dimensional printing system of claim 11 wherein the fluid spill containment vessel includes a pair of upper lips that extend along the first lateral axis and further comprising a pair of rails mounted to the lower side of the support plate that are configured to slidingly receive the pair of upper lips when the fluid spill containment vessel is slidingly mounted to the lower side of the support plate.

13. A three dimensional printing system for fabricating a three dimensional article of manufacture comprising:

a vertical support, the vertical support having a front side and a back side;

a motor system mounted to the back side of the vertical support;

a lead screw coupled to the motor system and extending vertically proximate to the back side of the vertical support;

a support plate affixed to the vertical support and extending from the front side along a first lateral axis from a proximal end to a distal end;

a resin vessel supported over the support plate, the resin vessel having a rear side corresponding to and proximate to the proximal end of the support plate;

a resin fluid outlet that is supported over the resin vessel along the rear side of the resin vessel;

a carriage mounted to the backside of the vertical support and engaged by the lead screw so as to be translated vertically along the vertical support;

a pair of fixture receiving arms that extend from the carriage along the first lateral axis from a proximal to a distal end, the support arms spaced apart along a second lateral axis that is perpendicular to the first lateral axis; and

a support fixture supported by and extending between the two fixture receiving arms.

14. The three dimensional printing system of claim 13 further comprising a light engine mounted to the vertical support whereby it projects pixelated light up to the resin vessel.

15. A three dimensional printing system for fabricating a three dimensional article of manufacture comprising:

a vertical support having a front side;

a support plate affixed to the vertical support and extending from the front side along a first lateral axis from a proximal end to a distal end;

a resin vessel supported over the support plate, the resin vessel having a rear side corresponding to and proximate to the proximal end of the support plate;

a resin fluid outlet that is supported over the resin vessel along the rear side of the resin vessel;

a vessel body having an inner edge defining a central opening; and

a transparent sheet that closes the central opening to define a lower bound for a body of resin to be contained in the resin vessel;

a carriage configured to be translated vertically along the vertical support;

a pair of fixture receiving arms that extend from the carriage along the first lateral axis from a proximal to a distal end, the support arms spaced apart along a second lateral axis that is perpendicular to the first lateral axis; and

a support fixture supported by and extending between the two fixture receiving arms;

a support bracket extending from the front side of a lower end of the vertical support; and

a light engine mounted to the support bracket and configured to project pixelated light upwardly through the transparent sheet to define a build plane within the resin.

16. The three dimensional printing system of claim 15 further comprising a fluid spill containment vessel mounted to a lower surface of the support plate.

17. The three dimensional printing system of claim 16 wherein the fluid spill containment vessel includes a window that laterally aligns with the central opening of the vessel body whereby the pixelated light from the light engine projects up through the window and to the transparent sheet.

18. The three dimensional printing system of claim 17 wherein fluid spill containment vessel has distal and proximal ends corresponding to the distal and proximal ends of the support plate, the fluid spill containment vessel generally tapers from the distal end to the proximal end to provide a containment trough to allow resin to drain away from the clear window and into the trough.