3D printing using spiral buildup

• US 9,321,215 B2
• Filed: 03/12/2014
• Issued: 04/26/2016
• Est. Priority Date: 03/12/2013
• Status: Active Grant

• Current Assignee: Douglas W. Farber, Orange Maker LLC
• Original Assignee: Orange Maker LLC
• Inventors: Dudley, Kurt
• Primary Examiner(s): Del Sole, Joseph S
• Assistant Examiner(s): Sultana, Nahida
• Application Number:
  US14/207,353
• Publication Number:
  US 20140265034A1
• Time in Patent Office: 776 Days
• Field of Search: 425/174.4, 425/375, 425/150, 425/112, 264/308, 264/401, 264/40.1, 264/497
• US Class Current: 1/1
• 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 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• 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 64/241 for rotary motion
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29K 2909/08 Glass
• 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

Methods, devices and systems for efficient 3D printing that address conventional inefficiencies while utilizing a single compact device are set forth. Some embodiments utilize a circular-shaped build area revolving symmetrically around a single center point utilizing a continuous helical printing process. In one embodiment a liquid photopolymer for solidification is deposited on a build platform to form the physical object The Build platform is continuously rotated and simultaneously raised in a gradual programmed manner. Focused from below the platform produces a single continuous “layer” of material deposited and bonded in a helical fashion.

Claims

1. A device for three-dimensional (3D) printing of structures in a vertical orientation, comprising:

a construction frame, a material dispenser with a flowable build material in said material dispenser, said build material being solidifiable, a construction area and a separate build platform, both positioned horizontally within said construction frame and configured for inverted build of a solidified 3D structure there between, said build platform spaced from said construction area a defined distance and continuously moveable vertically within, and configured to rotate in a continuous or semi-continuous manner, within said construction frame so as to provide a continuously increasing or stepwise increasing defined distance between said build platform and said construction area in each 360°

rotation of said build platform, the material dispenser being positioned to deliver a film of the flowable build material onto an exposure zone of an upper surface of the construction area, and a solidification mechanism positioned to deliver a solidifying medium to the flowable build material located on the exposure zone, said build platform configured to receive and retain the film of flowable build material delivered on to the upper surface of the construction area as the film of flowable build material solidifies and is moved said defined distance vertically upward as the build platform rotates within the construction frame;

wherein the device further comprising a drainage system.

2. The 3D printing device of claim 1, wherein said exposure zone of said construction area is transparent to a radiative source and said solidification mechanism is located below said transparent construction area.

3. The 3D printing device of claim 1, wherein said solidification mechanism comprises a radiative source.

4. The 3D printing device of claim 3, wherein said radiative source comprises one or more mirrors.

5. The 3D printing device of claim 4, wherein said one or more mirrors are moveable.

6. The 3D printing device of claim 3, wherein said radiative source comprises one or more LEDs.

7. The 3D printing device of claim 3, wherein said radiative source comprises one or more laser diodes.

8. The 3D printing device of claim 1, further comprising a second material dispenser.

9. The 3D printing device of claim 2, wherein said transparent substrate comprises glass.

10. The 3D printing device of claim 1, further comprising a mechanism for removing excess construction materials from the build platform.

11. The 3D printing device of claim 1, further comprising a material spreader configured to spread material evenly across the exposure zone of said construction area.

12. The 3D printing device of claim 1, wherein said build platform is configured to move up or down along a Z-axis.

13. The 3D printing device of claim 1, further comprising features for controlling the temperature of a space within the construction frame of the 3D printing device.

14. The 3D printing device of claim 1, further comprising regulated atmospheric conditions of a space within the construction frame of the 3D printing device.

15. The 3D printing device of claim 1, the material dispenser comprises one or more material cartridges for supplying and directing one or more materials.

16. The 3D printing device of claim 15, wherein said one or more material cartridges are removable and replaceable.

17. The 3D printing device of claim 1, further comprising an imaging unit.

18. The 3D printing device of claim 17, wherein said imaging unit comprises at least one image recording system.

19. A three-dimensional (3D) printing device, comprising:

a material dispenser for delivery of a film of a solidifyable liquid material;

a material solidification mechanism for causing the film of liquid to solidify, a build platform; and

a construction area having an exposure zone on an upper surface thereof, said build platform and said construction area configured for delivery of the film of solidifiable material to a space between the exposure zone and a lower surface of the build platform, said construction area and said build platform being positioned in substantially parallel planes, wherein said build platform is configured to rotate multiple 360°

turns in relationship to the construction area and continuously or semi-continuously increase, in each 360°

rotation, a defined distance between the build platform and the construction area such that rotation of said build platform causes portions of said film of solidifyable material delivered to said space and solidified into a structure to be retained on the lower surface of the build platform;

wherein the device further comprising a drainage system.

20. The 3D printing device of claim 19, further comprising a second material dispenser.

21. The 3D printing device of claim 19, wherein said exposure zone comprises a transparent substrate.

22. The 3D printing device of claim 21, wherein said transparent substrate comprises glass.

23. The 3D printing device of claim 19, further comprising a mechanism for removing excess construction materials from the build platform.

24. The 3D printing device of claim 19, further comprising a material spreader configured to spread material evenly across said exposure zone and said construction area.

25. The 3D printing device of claim 19, wherein said build platform is configured to move up and down along a Z-axis.

26. The 3D printing device of claim 19, further comprising temperature control systems for adjusting and maintaining a predetermined temperature in a build space within the 3D printing device.

27. The 3D printing device of claim 19, further comprising control systems for adjusting and maintaining a predetermined ambient conditions in a build space within the 3D printing device.

28. The 3D printing device of claim 19, where the material dispenser comprising one or more material containers and delivery means for supplying and directing material from the one or more material containers.

29. The 3D printing device of claim 28, wherein said material containers are removable and replaceable.

30. The 3D printing device of claim 19, further comprising an imaging unit.

31. The 3D printing device of claim 30, wherein said imaging unit comprise one or more devices for image capture and storage.