Apparatus and methods for handling materials in a 3-D printer

• US 7,828,022 B2
• Filed: 05/25/2007
• Issued: 11/09/2010
• Est. Priority Date: 05/26/2006
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Kinsley, Joshua, Sanchez, Jennifer, Davidson, Thomas, Hernandez, Andres T.
• Primary Examiner(s): Hopkins; Robert A
• Application Number:
  US11/807,329
• Publication Number:
  US 20080060330A1
• Time in Patent Office: 1,264 Days
• Field of Search: 141/18, 425/145, 264/497
• US Class Current: 141/18
• CPC Class Codes: B29C 31/02 Dispensing from vessels, e.g. hoppers into a mould cavity B29C31/04; large containers characterised by discharge means B65D88/28, B65D88/54
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/35 Cleaning
• CPC Class Codes: B29C 64/357 Recycling
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• 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: Y10T 137/86187 Plural tanks or compartments connected for serial flow

Abstract

The present invention is directed towards methods and apparatus for handling powder in a 3D printer. The invention includes a means of transporting powder from multiple sources to a powder dispensing apparatus with minimal user intervention, thus reducing contamination of the 3D printer and surrounding area with loose powder, while also providing a means of improving the recycling of powder for re-use.

Claims

1. A powder dispensing hopper for providing powder to a three-dimensional printer, the hopper comprising:

a chamber defined by the hopper for receiving powder, the chamber configured to be disposed relative to a build surface on a three-dimensional printer, the chamber defining at least one outlet sized and arranged to pass a predetermined amount of powder therethrough; and

a dispensing mechanism at least partially disposed within the chamber and adapted to push powder through the at least one outlet.

2. The hopper of claim 1, wherein the at least one outlet comprises a plurality of slots oriented longitudinally along a lowest surface of the chamber.

3. The hopper of claim 1, wherein a width of the outlet varies along a length thereof.

4. The hopper of claim 1, wherein a length of the outlet is variable to accommodate different size build surfaces.

5. The hopper of claim 1, wherein a position of the dispensing mechanism in the chamber is variable relative to the outlet.

6. The hopper of claim 1 further comprising a cover for opening and closing the at least one outlet.

7. The hopper of claim 1, wherein the dispensing mechanism is adapted to automatically push powder through the at least one outlet at predetermined intervals.

8. The hopper of claim 1, wherein the dispensing mechanism comprises a plurality of blades spaced about a radial axis oriented parallel to the at least one opening, the blades coupled to a rotary mechanism for rotating the blades proximate the at least one outlet to push the powder out of the at least one outlet.

9. The hopper of claim 1, wherein the chamber defines an inlet disposed proximate a top portion of the chamber for receiving powder.

10. The hopper of claim 9, wherein the chamber is coupled to a vacuum source for drawing powder into the chamber though the inlet from a remote source.

11. The hopper of claim 10, wherein the inlet comprises a diffuser for dispersing the powder entering the chamber.

12. The hopper of claim 10 further comprising a filtering system disposed between the inlet and the vacuum source.

13. The hopper of claim 12, wherein the filtering system comprises:

a filter adapted for air flow in two directions, the filter having at least two sides; and

a plenum disposed on one side of the filter, the plenum segmented to isolate portions of the filter from one another, the plenum adapted to expose the individual filter portions to at least one of a vacuum and a positive pressure.

14. The hopper of claim 13, wherein each plenum segment comprises a valve for connecting an associated filter portion to the vacuum source for drawing air carrying powder through the filter, the filter preventing the powder from passing therethrough.

15. The hopper of claim 14, wherein the valves are adapted to connect the associated filter portion to a positive pressure.

16. The hopper of claim 13, wherein the filter is coated with an abrasion resistant material.

17. The hopper of claim 13, wherein the plenum includes at least four segments.

18. The hopper of claim 15, wherein the filter portions are alternately exposed to the vacuum source and the positive pressure.

19. The hopper of claim 18, wherein each filter portion is alternately exposed to the vacuum source and the positive pressure sequentially.