Three-dimensional printer

• US 8,017,055 B2
• Filed: 02/23/2010
• Issued: 09/13/2011
• 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: Phillips, Robert A., Russell, David B., Davidson, Thomas
• Primary Examiner(s): Theisen; Mary Lynn F
• Application Number:
  US12/710,594
• Publication Number:
  US 20100151136A1
• Time in Patent Office: 567 Days
• Field of Search: None
• US Class Current: 264/308
• 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 a three-dimensional printer comprising:

a storage chamber for storing build material; and

a metering system to regulate the quantity of build material delivered from the storage chamber to an operating position,

wherein the metering system comprises a cylinder having a plurality of grooves inside a closely fitting tube having an entrance slot and an exit slot.

2. The apparatus of claim 1 wherein each groove defines a cavity to hold a particular volume of build material, the cylinder being rotatable inside the tube so that build material enters the cavity and is carried to the exit slot.

3. The apparatus of claim 1 further comprising a mechanism to break bridges and keep the build material flowing into the metering system.

4. The apparatus of claim 3 wherein the mechanism to break bridges includes a paddle wheel or a vibrating member.

5. The apparatus of claim 1 wherein at least a portion of the storage chamber and the metering system are mounted to a gantry capable of moving to the operating position.

6. The apparatus of claim 5 wherein the operating position is in front of a roller or a doctor blade to form a smooth layer.

11. The apparatus of claim 1, further comprising a flicker blade disposed proximate the exit slot.

7. A method of operating a three-dimensional printer, comprising:

storing build material in a storage chamber; and

regulating the quantity of build material delivered from the storage chamber to an operating position via a metering system,

wherein the metering system comprises a cylinder having a plurality of grooves inside a closely fitting tube.

8. The method of claim 7 further comprising breaking bridges to assist the flow of the build material into the metering system.

9. The method of claim 7 wherein the operating position is in front of a roller or a doctor blade to form a smooth layer.

12. The method of claim 7, further comprising removing the quantity of build material from the metering system.

10. An apparatus for operating a three-dimensional printer, comprising:

a means for storing build material in a storage chamber; and

a means for regulating the quantity of build material delivered from the storage chamber to an operating position via a metering system,

wherein the metering system comprises a cylinder having a plurality of grooves inside a closely fitting tube having an entrance slot and an exit slot.

13. The apparatus of claim 10, further comprising a flicker blade disposed proximate the exit slot.