Apparatus and methods for 3D printing

• US 7,291,002 B2
• Filed: 04/02/2004
• Issued: 11/06/2007
• Est. Priority Date: 05/23/2003
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Russell, David, Berlin, Andrew, Hernandez, Andres, Kinsley, Joshua
• Primary Examiner(s): Davis; Robert
• Assistant Examiner(s): Ewald; Maria Veronica
• Application Number:
  US10/817,159
• Publication Number:
  US 20040265413A1
• Time in Patent Office: 1,313 Days
• Field of Search: 425/375, 425/174.4, 264/308, 264/401, 700/119, 700/120
• US Class Current: 425/447
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• 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: 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: B41J 2/16532 by applying vacuum only
• CPC Class Codes: B41J 2/16535 using wiping constructions B41J2/16552 takes precedence
• CPC Class Codes: B41J 2/16552 using cleaning fluids
• CPC Class Codes: B41J 2/16579 Detection means therefor, e.g. for nozzle clogging
• CPC Class Codes: B41J 29/17 Cleaning arrangements
• CPC Class Codes: B41J 3/4073 Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects B41J3/283, B41J3/286 take precedence; building up a 3D object using individual droplets from jetting heads B29C64/112

Abstract

The invention relates to apparatus and methods for producing three-dimensional objects and auxiliary systems used in conjunction with the aforementioned apparatus and methods. The apparatus and methods involve continuously printing radially about a circular and/or rotating build table using multiple printheads. The apparatus and methods also include optionally using multiple build tables. The auxiliary systems relate to build material supply printhead cleaning diagnostics, and monitoring operation of the apparatus.

Claims

1. An apparatus for fabricating a three-dimensional object from a representation of the object stored in memory, the apparatus comprising:

a rotary annular build drum for receiving successive layers of a build material therein; and

an array of at least one printhead disposed above the annular build drum, wherein the at least one printhead is configured for selectively dispensing droplets of a liquid binder onto the build material.

2. The apparatus of claim 1, wherein the rotary annular build drum rotates continuously.

3. The apparatus of claim 1 further comprising a build material delivery system comprising:

a storage means for holding the build material; and

a conveying means for delivering the build material to the annular build drum.

4. The apparatus of claim 3 further comprising:

at least two storage chambers for holding at least two build material components separate from each other; and

a blender for mixing the build material components in a predetermined ratio prior to delivery to the annular build drum.

5. The apparatus of claim 1 further comprising a spreader for distributing die build material over at least a portion of the annular build drum.

6. The apparatus of claim 5, wherein the spreader comprises a counter-rotating roller.

7. The apparatus of claim 6, wherein the counter-rotating roller is skewed with respect to a radius of the rotary annular build drum to induce excess build material to migrate over an inner edge of the annular build drum.

8. The apparatus of claim 7 further comprising a sensor disposed below the inner edge of the annular build drum to detect an amount of the excess build material.

9. The apparatus of claim 8, wherein an amount of build material delivered to the annular build drum is adjusted in response to the amount of excess build material detected.

10. The apparatus of claim 1, wherein the array is configured to dispense droplets of the liquid binder over an entire surface of the annular build drum by continuous consecutive radial scanning motions of the at least one printhead.

11. The apparatus of claim 1, wherein the array is configured to dispense droplets of the liquid binder at substantially any radial location of the rotary annular build drum without adjustment.

12. The apparatus of claim 11, wherein the array can be adjusted incrementally radially.

13. The apparatus of claim 1, wherein the array can be displaced from a normal printing position for servicing.

14. The apparatus of claim 13, wherein the array can be displaced radially with respect to the rotary annular build drum.

15. The apparatus of claim 1, wherein the array includes redundant printheads.

16. The apparatus of claim 1, wherein the apparatus defines an opening for removing the three-dimensional object.

17. The apparatus of claim 16, wherein the three-dimensional object is removed through at least one of a bottom opening and a side opening of the annular build drum.

18. The apparatus of claim 1 further comprising a sensor to monitor at least one performance characteristic of the apparatus, wherein the characteristic is selected from the group consisting of print quality, printing errors, print speed, printhead condition, and drum position.

19. The apparatus of claim 18, wherein operation of the apparatus is modified in response to a signal received from the sensor.

20. The apparatus of claim 19, wherein the array is movable in response to the signal from the sensor.

21. The apparatus of claim 1 further comprising a plurality of rotary annular build drums.

22. An apparatus for fabricating a three-dimensional object from a representation of the object stored in memory, the apparatus comprising:

an annular build drum for receiving successive layers of a build material therein; and

an array of at least one printhead disposed above the annular build and movable relative to the annular build drum wherein the at least one printhead is configured for selectively dispensing droplets of a liquid binder onto the build material.

23. The apparatus of claim 22, wherein the array is movable over at least a portion of a build surface defined by the annular build drum.

24. The apparatus of claim 22, wherein the array is configured to dispense droplets of the liquid binder at substantially any radial location of the annular build drum by moving the array radially to a desired location.

25. The apparatus of claim 22, wherein the array moves continuously about the annular build drum.

26. The apparatus of claim 22, wherein the annular build drum is movable in a vertical direction.