Non-linear printhead assembly

• US 6,357,855 B1
• Filed: 02/25/1999
• Issued: 03/19/2002
• Est. Priority Date: 09/27/1996
• Status: Expired due to Term

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Brown, Joe M., Kerekes, Thomas A., Bedal, Bryan J. L.
• Primary Examiner(s): COLILLA, DANIEL JAMES
• Application Number:
  US09/260,522
• Time in Patent Office: 1,118 Days
• Field of Search: 347/20, 347/40, 264/109, 264/129, 264/130, 264/131, 264/132, 264/133, 264/134, 264/112, 264/113, 425/375
• US Class Current: 347/40
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

This invention relates to the formation of three-dimensional objects on substantially layer-by-layer basis with enhanced resolution. The invention utilizes a unique offset printhead containing groups of jets to selectively deposit a hot-melt material.

Claims

1. A printhead assembly for a three-dimensional printer comprising:

a non-linear printhead having a width and a length and a plurality of jets in a multi-jet grouping, said non-linear printhead length having a lengthwise axis,

a dispensing carriage having a width and a length, said dispensing carriage length having a lengthwise axis,

said printhead having at least one of its jets in the multi-jet grouping positioned off line in a non-linear fashion and being connected with said dispensing carriage such that the lengthwise axis of said non-linear printhead and the lengthwise axis of said dispensing carriage intersect when positioned in the same plane, and

the printhead containing rows and columns of jets and the jets in at least one row comprising at least one group of four jets, three of the four jets in the group being linearly aligned and the fourth jet in the group not being linearly aligned, the fourth jet having an offset angle of between eight and ten degrees.

2. The printhead assembly for a three-dimensional printer according to claim 1, wherein one or more of the jets in the printhead assembly are gravitationally oriented to print in an X-Y plane.

3. A printhead assembly for a three-dimensional printer comprising:

a printhead having a width and a length and a plurality of jets in a multi-jet grouping, said printhead length having a lengthwise axis,

a dispensing carriage having a width and a length, said dispensing carriage length having a lengthwise axis,

said printhead having at least one of its jets in the multi-jet grouping positioned off line in a non-linear fashion and being connected with said dispensing carriage and provided further that the lengthwise axis of said printhead and the lengthwise axis of said dispensing carriage are not parallel and are not coincidental, and

the printhead containing rows and columns of jets and the jets in at least one row comprising at least one group of four jets, three of the four jets in the group being linearly aligned and the fourth jet in the group not being linearly aligned.

4. The printhead assembly for a three-dimensional printer according to claim 3, wherein one or more of the jets in the printhead assembly are gravitationally oriented to print in an X-Y plane.

5. A method of three-dimensional printing to obtain a three-dimensional object including utilizing a printhead assembly comprising:

moving a dispensing carriage having a width and a length along a path of travel, the dispensing carriage length having a lengthwise axis,

mounting a printhead to the dispensing carriage, the printhead having at least one of its jets in a multi-jet grouping positioned off line in a non-linear fashion and being connected with said dispensing carriage such that the lengthwise axis of said printhead and the lengthwise axis of said dispensing carriage intersect when positioned in the same plane,

the printhead further containing rows and columns of jets and the jets in at least one row comprise at least one group of four jets, three of the four jets in the group being linearly aligned and the fourth jet in the group not being linearly aligned,

gravitationally orienting the printhead to print in an X-Y plane, and

jetting a material from the printhead on successive occasions to obtain a three-dimensional object.

6. A method of three-dimensional printing to obtain a three-dimensional object including utilizing a printhead assembly comprising:

moving a dispensing carriage having a width and a length along a path of travel, the dispensing carriage length having a lengthwise axis,

mounting a printhead to the dispensing carriage, the printhead having at least one of its jets in a multi-jet grouping positioned off line in a non-linear fashion and being connected with said dispensing carriage such that the lengthwise axis of said printhead and the lengthwise axis of said dispensing carriage are not parallel and are not coincidental, the printhead further containing rows and columns of jets and the jets in at least one row comprise at least one group of four jets, three of the four jets in the group being linearly aligned and the fourth jet in the group not being linearly aligned, and

jetting a material from the printhead on successive occasions to obtain a three-dimensional object.

7. The method of three-dimensional printing according to claim 6, wherein the printhead is gravitationally oriented to print in an X-Y plane.

8. A method of three-dimensional printing comprising employing an offset printhead and a moveable printing platform wherein the offset printhead, when in operation, moves in the direction of an X-axis (Y-Z plane) and the moveable printing platform moves, when in operation, in the direction of a Y-axis (X-Z plane);

and printing with the printhead so the printhead deploys a greater number of droplets per inch in the direction of the X-axis and a lesser number of droplets per inch in the direction of the Y-axis wherein the ratio of droplets per inch in the direction of the X-axis to the number of droplets per inch in the direction of the Y-axis is about 1.05 to about 1.40.

9. The method of three-dimensional printing according to claim 8, wherein the ratio of droplets per inch in the direction of the X-axis to the number of droplets per inch in the direction of the Y-axis is about 1.1 to about 1.35.