Systems and methods of solid freeform fabrication with translating powder bins

• US 7,296,990 B2
• Filed: 10/14/2005
• Issued: 11/20/2007
• Est. Priority Date: 10/14/2005
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Devos, John A., Lambright, Terry M., Nielsen, Jeffrey A., Cruz-Uribe, Tony S., Collins, David C.
• Primary Examiner(s): Gupta; Yogendra N.
• Assistant Examiner(s): Ewald; Maria Veronica
• Application Number:
  US11/251,159
• Publication Number:
  US 20070087071A1
• Time in Patent Office: 767 Days
• Field of Search: 425/375, 264/308, 264/401, 700/118
• US Class Current: 425/375
• 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 50/02 for controlling or regulating additive manufacturing processes

Abstract

Solid freeform fabrication systems, powder supply bins for solid freeform fabrication systems, and methods of solid freeform fabrication are disclosed. One exemplary solid freeform fabrication system includes a powder supply bin, a build bin, a roller, and a print head disposed above the build bin that deposits a binder onto the powder in the build bin in a preselected pattern, the supply bin and/or the build bin translating in a x- and/or y-direction relative to the print head.

Claims

1. A solid freeform fabrication (SFF) system comprising:

a powder supply bin;

a build bin adjacent the powder supply bin;

a printhead disposed above the build bin that deposits a binder onto the powder in the build bin in a preselected pattern;

a roller disposed adjacent the printhead, the roller configured to distribute and compress the powder at a top surface of the removable powder supply bin and the build bin to a desired thickness; and

wherein the powder supply bin and the build bin are attached to a stage that translates the powder supply bin and the build bin in a y-axis relative to the printhead.

2. The SFF system of claim 1, wherein the stage comprises a mechanical drive.

3. The SFF system of claim 1, wherein the stage comprises a mechanical drive that is selected from the group consisting of:

a servo motor, a linear motor, a stepper motor, a synchronous motor, a D.C. motor, and a fluid motor.

4. The SFF system of claim 1, wherein the print head translates in an x-axis relative to the bins.

5. The SFF system of claim 1, wherein the print head translates in an x-axis relative to the bins via a belt drive.

6. The SFF system of claim 1, wherein each of the powder supply bin and the build bin comprises:

side walls made of a material chosen from one of the group consisting of;

acetals, acrylics, terpolymers, alkyds, melamines, phenolic resins, polyarylates, polycarbonates, polyethylene, polypropylene, polyphenylene sulfide, polystyrene, polyvinyl chloride, styrene acrylonitrile, polyphenylsulfone, polyethersulfones, polyetherketones, unsaturated polyesters, polytetrafluoroethylene, liquid crystalline polymer, polyurethanes, urea-formaldehyde molding compounds, a metal, a metal alloy, and combinations thereof; and

a piston bottom configured to be acted on by a linear motion actuator of the SFF system.

7. The SFF system of claim 1, wherein each of the powder supply bin and the build bin comprises a bag compartment constructed of a flexible polymeric material.

8. The SFF system of claim 1, wherein each of the powder supply bin and the build bin comprises a bag compartment, the bag compartment being constructed of a polymeric film of one of the group consisting of:

polyvinyl chloride, polyethylene, polyethylene copolymers, polyethylene naphthalate, polyamide, polyester, polyarylates, polybutylene terepthalate, polypropylene, polyurethane, cellulosics, and polysaccharides.

9. The SFF system of claim 1,

wherein at least one of the build bin or the powder supply bin comprises a memory that communicates information about the powder to a controller for the solid freeform fabrication system, and

wherein the system comprises a sensor that is configured to receive information from the memory on the powder supply bin.

10. A solid freeform fabrication (SFF) system comprising:

a stationary powder supply bin;

a build bin adjacent the powder supply bin, wherein the build bin comprises a moveable surface in the z-direction, on which an object is fabricated;

a roller disposed above the powder supply bin and the build bin, the roller being incorporated into a movable stage and configured to distribute and compress the powder at a top surface of the stationary powder supply bin and the build bin to a desired thickness; and

a print head disposed above the build bin that deposits a binder onto the powder in the build bin in a preselected pattern;

wherein the build bin is configured to translate in a y-axis relative to the print head.

11. The SFF system of claim 10, wherein the stage comprises a mechanical drive.

12. The SFF system of claim 10, wherein the stage comprises a mechanical drive that is selected from the group consisting of:

a servo motor, a linear motor, a stepper motor, a synchronous motor, a D.C. motor, and a fluid motor.

13. The SFF system of claim 10, wherein the print head translates in an x-axis relative to the bins.

14. The SFF system of claim 10, wherein the print head translates in an x-axis relative to the bins via a belt drive.

15. The SEE system of claim 10, wherein the build bin further comprises a memory that communicates information about the powder to a controller for the solid freeform fabrication system, wherein the information is one of the group consisting of:

powder volume, powder type, bin manufacturer, allowable binder types for the powder, recommended spread-roller rotation speed, supply bin z-step size, expiration date of the powder, drop volume needed for a given layer thickness, and setting time.

16. The SEE system of claim 10, wherein the movable stage incorporating the roller translates independently of the build bin.

17. The SFF system of claim 10, wherein the movable stage incorporating the roller is static.

18. A solid freeform fabrication system comprising:

means for dispensing powder from a powder supply bin onto a layer on a build platform;

means for building an object by layers in the build bin, wherein each layer is formed by ejecting a binder with an inkjet print head onto the layer of powder in the build bin;

means for translating the build platform in a downward z-direction as the object is built;

means for translating the build platform a y-direction relative to the print head; and

means for translating the print head in an x-direction relative to the build platform.

19. The system of claim 18, further comprising:

means for containing the powder in the powder bin;

means for pushing the powder upward in the supply bin; and

means for allowing the powder to build in layers in the build bin.

20. The system of claim 18, further comprising:

means for communicating information about the powder to a means for controlling the system; and

means for receiving information from the sensor on the powder supply bin.