Three-dimensional printer

• US 7,037,382 B2
• Filed: 09/27/2002
• Issued: 05/02/2006
• Est. Priority Date: 12/20/1996
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Kinsley, Joshua P., Zengerle, Walter H. III, Davidson, Thomas, Phillips, Robert A., Berlin, Andrew, Russell, David B., Sweet-Block, Benjamin Daniel, Kisai, Darul, Roche, Kevin, Hernandes, Andres T.
• Primary Examiner(s): Theisen, Mary Lynn
• Application Number:
  US10/260,224
• Publication Number:
  US 20040012112A1
• Time in Patent Office: 1,313 Days
• Field of Search: 134/21, 134/37, 134/198, 134/104.2, 264/308
• US Class Current: 134/21
• 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 64/165 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: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29K 2995/0021 Multi-coloured
• 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 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B41J 2/01 Ink jet
• CPC Class Codes: B41J 2/16523 Waste ink collection from caps or spittoons, e.g. by suction
• CPC Class Codes: B41J 2/16535 using wiping constructions B41J2/16552 takes precedence
• CPC Class Codes: B41J 2/16541 Means to remove deposits from wipers or scrapers
• CPC Class Codes: B41J 2/16552 using cleaning fluids

Abstract

A three-dimensional printer uses inkjet-type printheads to rapidly prototype, or print, a three-dimensional model. A powder feeder includes a conveyor system and a metering system to deliver powder to a build area in measured quantities. The powder feeder also includes a vacuum system for loading powder into a feed reservoir or chamber. The vacuum system can also be used to cleanup excess powder. Other powder control features include powder gutters and magnetic powder plows. During printing, a cleaning system operates to remove powder from the printheads. In the event of a printhead or jet failure, the failure can be detected and corrective measures taken automatically. After printing, the model can be depowdered and infiltrated in an enclosure.

Claims

1. An apparatus for removing loose powder from the surface of a three-dimensional printed object, comprising:

an enclosure for holding the object;

a blower for creating an airflow;

at least one filter for removing powder from the airflow;

a system of ducts for channeling the airflow to the enclosure; and

a tool coupled to the ducts for blowing compressed air onto the object.

2. The apparatus of claim 1 wherein the ducts direct at least one portion of the exhaust of the blower across the opening of the enclosure to form an air curtain inhibiting powder from being ejected from the enclosure.

3. The apparatus of claim 2 wherein the ducts direct at least a portion of the exhaust of the blower throughout the enclosure to inhibit stagnant air pockets and create a generalized airflow within the enclosure.

4. The apparatus of claim 1 wherein the enclosure includes a build chamber for fabricating the object.

5. The apparatus of claim 1 further comprising a back pulse cleaner to remove powder from the filter and a chamber for receiving the removed powder.

6. The apparatus of claim 5 wherein the powder removed from the filter is automatically recycled by a vacuum system.

7. The apparatus of claim 1 further comprising a powder gutter.

8. The apparatus of claim 7 further comprising a moveable plow member in communication with the powder gutter.

9. A method of removing loose powder from the surface of a three-dimensional printed object, the method comprising:

holding the object in an enclosure;

creating an airflow;

removing powder from the airflow with at least one filter;

channeling the airflow to the enclosure through a system of ducts; and

operating a tool coupled to the ducts for blowing compressed air onto the object.

10. The method of claim 9 wherein channeling comprises directing at least one portion of the exhaust of the blower across the opening of the enclosure to form an air curtain inhibiting powder from being ejected from the enclosure.

11. The method of claim 10 wherein channeling comprises directing at least a portion of the exhaust of the blower throughout the enclosure to inhibit stagnant air pockets and create a generalized airflow within the enclosure.

12. An apparatus for removing loose powder from the surface of a three-dimensional printed object, comprising:

a means for holding the object in an enclosure;

a means for creating an airflow;

a means for removing powder from the airflow with at least one filter;

a means for channeling the airflow to the enclosure through a system of ducts; and

a means for operating a tool coupled to the ducts for blowing compressed air onto the object.