Three-dimensional printer

• US 7,686,995 B2
• Filed: 08/15/2008
• Issued: 03/30/2010
• 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., Berlin, Andrew, Sweet-Block, Benjamin Daniel, Kisai, Darul, Roche, Kevin, Zengerle, Walter H. III, Davidson, Thomas, Phillips, Robert A., Hernandez, Andres T., Russell, David B.
• Primary Examiner(s): Theisen; Mary Lynn F
• Application Number:
  US12/192,412
• Publication Number:
  US 20090011066A1
• Time in Patent Office: 592 Days
• Field of Search: None
• US Class Current: 264/113
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/33 translatory in the deposition plane
• CPC Class Codes: B22F 12/57 Metering means
• CPC Class Codes: B22F 12/60 Planarisation devices; Compression devices
• 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 41/36 Feeding the material on to the mould, core or other substrate
• 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: 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 2/155 for line printing
• CPC Class Codes: B41J 2/16541 Means to remove deposits from wipers or scrapers
• CPC Class Codes: B41J 2/16552 using cleaning fluids
• CPC Class Codes: B41J 2/17513 Inner structure
• CPC Class Codes: B41J 2/17556 Means for regulating the pressure in the cartridge
• CPC Class Codes: B41J 2/17596 Ink pumps, ink valves
• CPC Class Codes: B41J 2002/14475 characterised by nozzle shapes or number of orifices per chamber
• CPC Class Codes: B41J 2202/20 : Modules
• CPC Class Codes: Y02P 10/25 : Process efficiency

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 fabricating a three-dimensional object comprising a gravity-feed system for delivering a binder to a layer of build material.

2. A method of fabricating a three-dimensional object, comprising:

in a feed reservoir, storing a supply of build material usable to fabricate the object;

operating a vacuum system having a vacuum inlet plumbed to the feed reservoir;

in a build chamber, receiving incremental layers of the build material from the feed reservoir;

depositing binder onto the incremental layers of the build material via a printhead;

supplying a quantity of binder to the printhead with a gravity-feed delivery mechanism;

in an overflow cavity, receiving an excess quantity of build material transferred from the feed reservoir but not received by the build chamber;

moving build material along a conveyor from the feed reservoir toward the build chamber;

regulating the quantity of build material delivered from the conveyor to the build chamber via a metering system;

holding the object in an enclosure; and

spraying infiltrant on the object in the enclosure.

3. The method of claim 2 further comprising:

creating an airflow with a blower;

removing build material from the airflow with at least one filter;

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

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

4. The method of claim 2 further comprising removing infiltrant aerosols from the enclosure with a filtration system.

5. The method of claim 2 further comprising transferring build material from the source of build material to the feed reservoir through the vacuum inlet.

6. The method of claim 5 wherein the source of build material is at least one of a container of build material, the build chamber;

the overflow cavity, or an area proximate to the feed reservoir or the build chamber.

7. The method of claim 6 automatically transferring build material from the overflow cavity to the feed reservoir.

8. The method of claim 6 further comprising injecting air into the container of build material.

9. The method of claim 2 further comprising filtering particles from the build material with the vacuum system.

10. The method of claim 2 further comprising:

disposing at least one filter within the vacuum system; and

cleaning the at least one filter.

11. The method of claim 2 wherein there are a plurality of filters, and cleaning includes operating a valve system to direct a reversed airflow sequentially through each of the filters to remove accumulated particles.

12. The method of claim 11 further comprising maintaining airflow and vacuum inside the vacuum with at least one filter.

13. A method of fabricating a three-dimensional object, comprising delivering a binder to a layer of build material through a gravity-feed delivery system.