Automated 3D build processes

• US 8,668,859 B2
• Filed: 10/16/2012
• Issued: 03/11/2014
• Est. Priority Date: 08/18/2010
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: MakerBot Industries, LLC (Ultimaker BV)
• Inventors: Pettis, Nathaniel B.
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Brown, II, David N
• Application Number:
  US13/652,608
• Publication Number:
  US 20130073073A1
• Time in Patent Office: 511 Days
• Field of Search: 264/401, 264/405, 264/308, 425/375, 425/110, 425/113
• US Class Current: 264/308
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/176 Sequentially
• CPC Class Codes: B29C 64/295 Heating elements
• 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

Abstract

A conveyor or other transport mechanism is provided to support multiple, sequential builds from a three-dimensional fabrication machine. The conveyor may be heated/cooled, coated, or otherwise treated to assist in adhesion during a build, as well as removal of objects after a build. Each fabricated object may be automatically removed from the conveyor as the conveyor moves in order to restore a buildable surface for fabrication of additional objects.

Claims

1. An apparatus comprising:

a build platform including a surface that is rigid and substantially planar, the surface including a plurality of areas;

an extruder including a chamber to receive a build material and an extrusion tip that extrudes the build material at a controlled volumetric rate;

a x-y-z positioning assembly adapted to three-dimensionally position the extrusion tip within the working volume;

a controller electrically coupled to each of the build platform, the extruder, and the x-y-z positioning assembly, the controller operable to control the build platform, the extruder, and the x-y-z positioning assembly to fabricate an object in three-dimensions from the build material; and

a plurality of heating elements disposed within the build platform, each one of the plurality of heating elements associated with a corresponding one of the plurality of areas of the surface of the build platform, each one of the plurality of heating elements coupled in a communicating relationship with the controller, wherein the controller is configured to independently control each one of the plurality of heating elements to provide different heating to each one of the plurality of areas of the surface of the build platform.

2. The apparatus of claim 1 wherein at least one of the plurality of heating elements includes a resistive element to convert electrical current into heat.

3. The apparatus of claim 1 wherein at least one of the plurality of heating elements includes a Peltier effect device.

4. The apparatus of claim 1 further comprising at least one cooling element coupled to the controller and configured to provide active cooling to an area of the build platform.

5. The apparatus of claim 1 wherein the plurality of heating elements includes at least one gas heating device.

6. The apparatus of claim 1 further comprising at least one stream of heated gas directed toward the build platform and controllable to heat the build platform.

7. The apparatus of claim 1 further comprising at least one stream of cooled gas directed toward the build platform and controllable to cool the build platform.

8. The apparatus of claim 1 further comprising at least one sensor to detect a temperature of the build platform.

9. The apparatus of claim 1 further comprising at least one radiant heater configured to heat the working volume during a build.

10. The apparatus of claim 1 further comprising at least one radiant heater configured to maintain the object at a fixed, elevated temperature during a build.

11. The apparatus of claim 1 wherein the plurality of heating elements provide independent control over cooling the plurality of areas of the surface of the build platform.

12. The apparatus of claim 1 further comprising a conveyor to controllably move the object out of the working volume.

13. The apparatus of claim 1 wherein the plurality of heating elements are controllable to heat at least one of the plurality of areas of the surface of the build platform to at least about one hundred degrees Celsius.

14. A method comprising:

providing a build platform having a surface that is substantially planar, the surface including a plurality of areas, the build platform passing through a working volume of a three-dimensional printer;

independently controlling a plurality of heating elements for the build platform to provide different heating to each one of the plurality of areas of the surface of the build platform; and

fabricating an object on the build platform, wherein fabricating the object includes creating the object from a number of layers of a material, each one of the number of layers having a two-dimensional shape corresponding to a cross-section of the object.

15. The method of claim 14 further comprising actively cooling the build platform after fabricating the object.

16. The method of claim 14 further comprising moving the object out of the working volume with a conveyor after fabricating the object.

17. A computer program product for controlling a three-dimensional printer, the computer program product comprising computer executable code embodied in a non-transitory computer-readable medium that, when executing on one or more computing devices, performs the steps of:

controlling a three-dimensional printer to fabricate an object on a build platform within a working volume of the three-dimensional printer, the build platform having a surface that is substantially planar, the surface including a plurality of areas, wherein fabricating the object includes creating the object from a number of layers of a material, each one of the number of layers having a two-dimensional shape corresponding to a cross-section of the object; and

independently controlling a plurality of heating elements for the build platform to provide different heating to each one of the plurality of areas of the surface of the build platform.

18. The computer program product of claim 17 further comprising code that performs the step of moving the object out of the working volume with a conveyor after completing a fabrication of the object.