Three-dimensional printing and scanning system and method

• US 9,364,995 B2
• Filed: 03/15/2013
• Issued: 06/14/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Matterrise Incorporated
• Original Assignee: Matterrise Incorporated
• Inventors: Roberts, Arthur L. IV, Kiloh, Jerred
• Primary Examiner(s): Kennedy, Timothy
• Application Number:
  US13/844,046
• Publication Number:
  US 20140271964A1
• Time in Patent Office: 1,187 Days
• Field of Search: 425/375, 264/401
• 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 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes

Abstract

Disclosed herein are systems and methods for three-dimensional (3D) printing and scanning (or rapid prototyping). For example, presented herein are 3D printing and scanning systems and methods to create a 3D replica of a 3D object on a build surface. Movements and/or controls of the system are generally based on polar coordinates relative to a center of a build surface. System components may generally include: (1) a rotatable build surface; (2) a media extruder positioned over the build surface; (3) a heating element to melt media as it is drawn into the extruder; (4) an extruder positioning system coupled to the extruder and configured to move the extruder over the build surface based on polar coordinates relative to a center of the build surface; and (5) an optical scanning system for scanning of a 3D object to obtain a plurality of two-dimensional (2D) images of the 3D object.

Claims

1. A three-dimensional (3D) printing and scanning system configured to create a 3D replica of a 3D object on a build surface, with movements and/or controls based on polar coordinates relative to a center of a build surface, comprising:

an uninterrupted circular planar build surface which is rotatable about a central axis of rotation;

a first motor coupled to the build surface such that actuation of the first motor rotates the build surface;

an extruder positioned over the build surface, wherein the extruder includes

a filament input for receiving a filament,

a second motor for drawing the filament into the extruder,

a heating element to melt the filament as it is drawn into the extruder, and

an output nozzle for depositing filament melt onto the build surface;

an extruder positioning system coupled to the extruder and configured to move the extruder over the build surface based on polar coordinates relative to a center of the build surface, wherein the extruder positioning system includes;

a third motor for moving the extruder radially relative to the center of the build surface, and

a fourth motor for moving the extruder axially relative to the build surface;

an optical scanning system comprising one or more cameras positioned to obtain a plurality of two-dimensional (2D) images of a 3D object; and

a microcontroller coupled to a data transmission system and configured to execute control code, wherein execution of the control code actuates the first motor, the second motor, the third motor, the fourth motor, and the heating element in a coordinate fashion to create a 3D replica of the 3D object on the build surface.

2. The printing and scanning system of claim 1, wherein the optical scanning system includes a moving element for moving the one or more cameras axially or radially with respect to the build surface in order to obtain multiple images of the 3D object.

3. The printing and scanning system of claim 2, wherein the moving element for moving the one or more cameras incorporates the use of the third and fourth motors.

4. The printing and scanning system of claim 1, wherein at least one of the one or more cameras is coupled to the extruder such that movement of the extruder results in movement of the camera.

5. The printing and scanning system of claim 1, wherein the data transmission system is coupled to the optical scanning device and configured to send the plurality of 2D images to an external processor to convert the plurality of 2D images into a 3D surface reconstruction of the 3D object, and receive control code from the external processor, wherein the control code is based on the 3D surface reconstruction.

6. The printing and scanning system of claim 1, further comprising:

an image processor communicably coupled to the microcontroller, wherein the image processor receives the plurality of 2D images, converts the plurality of 2D images into a 3D surface reconstruction of the 3D object, and generates control code based on the 3D surface reconstruction.

7. The printing and scanning system of claim 1, wherein the first motor is a DC motor, and the second, third, and fourth motors are stepper motors.

8. A three-dimensional (3D) printing and scanning system based on polar coordinates, comprising:

an uninterrupted circular planar build surface which is rotatable about a central axis of rotation;

an extruder positioned over the build surface for depositing filament melt onto the build surface;

an extruder positioning system coupled to the extruder and configured to move the extruder over the build surface based on polar coordinates relative to a center of the build surface serving as a center of origin;

an optical scanning system comprising one or more cameras positioned to obtain a plurality of two-dimensional (2D) images of a 3D object; and

a microcontroller coupled to the extruder positioning system and configured to execute a control code, wherein execution of the control code actuates the extruder positioning system to move the extruder in axial and radial directions relative to the center of the build surface.

9. The system of claim 8, further comprising:

a first motor coupled to the build surface such that actuation of the motor rotates the build surface.

10. The system of claim 9, wherein rotation of the build surface is one-directional.

11. The system of claim 9, wherein the build surface is configured to rotate about the central axis of rotation in a first direction and non-simultaneously, in a second direction.

12. The system of claim 8, wherein the extruder further comprises:

a filament input for receiving a filament;

a first motor for drawing the filament into the extruder;

a heating element to melt the filament as it is drawn into the extruder; and

an output nozzle for depositing the filament melt onto the build surface.

13. The system of claim 8, wherein the extruder positioning system further comprises:

a first motor for moving the extruder radially; and

a second motor for moving the extruder axially.

14. The system of claim 8, further comprising:

a scanning device positioned to obtain a plurality of two-dimensional (2D) images of a 3D object; and

a data transmission system coupled to the scanning device and configured to send the plurality of 2D images to an external processor, and receive control code from the external processor.

15. The system of claim 14, wherein the control code includes commands for controlling the filament melt being processed by the extruder.

16. The system of claim 14, wherein the control code includes commands for controlling the radial position of the extruder relative to the center of the build surface.

17. The system of claim 14, wherein the control code includes commands for controlling the axial position of the extruder relative to the build surface.

18. The system of claim 14, wherein the plurality of images are obtained by the scanning device while the 3D object is rotated on the build surface.

19. A three-dimensional (3D) printing and scanning system, comprising:

an uninterrupted circular planar build surface which is rotatable about a central axis of rotation;

an extruder positioned over the build surface for depositing media melt onto the build surface;

an optical scanning system comprising one or more cameras positioned to obtain a plurality of two-dimensional (2D) images of a 3D object; and

a positioning element for controlling the position of the extruder, relative to the build surface, based on polar coordinates;

wherein the positioning element for controlling the position of the extruder further comprises a motor coupled to the extruder to move the extruder radially relative to a center of the build surface.

20. The system of claim 19, wherein the extruder further comprises:

a media input for receiving media;

a motor for drawing the media into the extruder;

a heating element to melt the media as it is drawn into the extruder; and

an output nozzle for depositing the media melt onto the build surface.

21. The system of claim 19, further comprising:

a first motor coupled to the build surface and configured to control a rotational position of the build surface.