Solid imaging systems, components thereof, and methods of solid imaging

• US 9,034,237 B2
• Filed: 09/25/2012
• Issued: 05/19/2015
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Sperry, Charles R., McNamara, Dennis F., Johnson, Martin Alan, Gregory, Richard Ora II
• Primary Examiner(s): HINDENLANG, ALISON L
• Application Number:
  US13/625,946
• Publication Number:
  US 20140084517A1
• Time in Patent Office: 966 Days
• Field of Search: 425/218, 425/219
• US Class Current: 264/401
• 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 64/214 Doctor blades
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• 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

Abstract

There is provided solid imaging methods and apparatus for making three-dimensional objects from solid imaging material. A tray with a film bottom is provided to hold solid imaging material that is selectively cured into cross-sections of the three-dimensional object being built. A coater bar is moved back and forth over the film to remove any uncured solid imaging material from a previous layer and to apply a new layer of solid imaging material. A sensor is provided to measure the amount of resin in the tray to determine the appropriate amount of solid imaging material to be added, from a cartridge, for the next layer. A shuttle, which covers the tray when the exterior door to the solid imaging apparatus is opened for setting up a build or removing a three-dimensional object, can also be used to move the coater bar and to selectively open one or more valves on the cartridge to dispense the desired amount of solid imaging material.

Claims

1. A solid imaging apparatus for making a three-dimensional object from solid imaging material, the solid imaging apparatus comprising:

a cartridge including a supply of solid imaging material;

a tray that holds solid imaging material dispensed from the cartridge;

a coater bar for applying the dispensed solid imaging material on the tray;

a moving portion connected to the coater bar to selectively move the coater bar along an x-axis within the solid imaging apparatus; and

an imager that projects actinic radiation onto a layer of solid imaging material in the tray to selectively cure the layer of solid imaging material,

wherein the coater bar comprises;

a first scraping edge extending generally along a y-axis within the solid imaging apparatus;

a second layering edge extending generally along the y-axis within the solid imaging apparatus; and

a connection portion adapted to connect the coater bar with the moving portion, wherein the connection portion defines at least two connection positions for connecting the coater bar to the moving portion, and wherein a first connection position causes the first scraping edge to be the lowermost portion of the coater bar and the second connection position causes the second layering edge to be the lowermost portion of the coater bar.

2. A solid imaging apparatus according to claim 1, wherein the first scraping edge defines a doctor blade edge.

3. A solid imaging apparatus according to claim 1, wherein the second layering edge comprising a plurality of tabs extending generally orthogonal to the second layering edge.

4. A solid imaging apparatus according to claim 3, wherein the plurality of tabs are positioned on the leading edge of the coater bar when the coater bar is in the second connection position.

5. A solid imaging apparatus according to claim 4, wherein a trailing edge of the coater bar in the second connection position defines a gap between the portion of the second layering edge extending generally along the y-axis and a bottom of the plurality of tabs extending generally orthogonal to the second layering edge.

6. A solid imaging apparatus according to claim 5, wherein the plurality of tabs define a geometry, as viewed along the z-axis, adapted to reduce disturbances in the solid imaging material that the tabs contact during movement of the coater bar.

7. A solid imaging apparatus according to claim 1, wherein the connection portion defines a wedge-slot extending along the y-axis and comprising two surfaces that are generally at an angle to the other.

8. A coater bar for use in a solid imaging apparatus having at least one moving portion therein, the coater bar comprising:

a first scraping edge extending generally along a y-axis within the solid imaging apparatus;

a second layering edge extending generally along the y-axis within the solid imaging apparatus; and

a connection portion adapted to connect the coater bar with the moving portion, wherein the connection portion defines at least two connection positions, and wherein a first connection position causes the first scraping edge to be the lowermost portion of the coater bar and the second connection position causes the second layering edge to be the lowermost portion of the coater bar.

9. A coater bar according to claim 8, wherein the first scraping edge defines a doctor blade edge.

10. A coater bar according to claim 8, wherein the second layering edge comprising a plurality of tabs extending generally orthogonal to the second layering edge.

11. A coater bar according to claim 10, wherein a trailing edge of the coater bar in the second connection position defines a gap between the portion of the second layering edge extending generally along the y-axis and a bottom of the plurality of tabs extending generally orthogonal to the second layering edge.

12. A coater bar according to claim 8, wherein the connection portion defines a wedge-slot extending along the y-axis and comprising two surfaces that are generally at an angle to the other.