Method for printing three-dimensional parts with additive manufacturing systems using scaffolds

• US 9,511,547 B2
• Filed: 08/16/2012
• Issued: 12/06/2016
• Est. Priority Date: 08/16/2012
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Swanson, William J., Mannella, Dominic F.
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Lindsay, Bernard G
• Application Number:
  US13/587,012
• Publication Number:
  US 20140052287A1
• Time in Patent Office: 1,573 Days
• Field of Search: None
• 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 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 2219/49023 3-D printing, layer of powder, add drops of binder in layer, new powder

Abstract

A method for printing a three-dimensional part with an additive manufacturing system, comprising printing the three-dimensional part in a layer-by-layer manner along a printing axis in the additive manufacturing system, printing a scaffold in a layer by layer manner along the printing axis along with the printing of the three-dimensional part, and bracing the three-dimensional part laterally relative to the printing axis with the scaffold while printing the three-dimensional part.

Claims

1. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:

printing the three-dimensional part in a layer-by-layer manner in a build plane along a printing axis in the additive manufacturing system;

printing a scaffold with a sacrificial material in a layer by layer manner in the build plane along the printing axis while also printing the three-dimensional part and wherein more than one layer of scaffold is printed in the build plane wherein the scaffold comprises a ribbon portion having a wave pattern such that the layer of the scaffold is connected to the layer of the three-dimensional part at one or more tangential locations of the ribbon portion, the locations providing periodic contact points spaced from one another a selected distance;

indexing the scaffold and the three-dimensional part along the printing axis; and

wherein the scaffold braces the three-dimensional part laterally relative to the printing axis such that the scaffold addresses forces parallel to the build plane while printing an additional portion of the three-dimensional part.

2. The method of claim 1, wherein the printed scaffold further comprises a base connected to the ribbon portion opposite of the three-dimensional part.

3. The method of claim 1, wherein the scaffold has one or more walls that are each about one road-width thick.

4. The method of claim 1, wherein the three-dimensional part and the scaffold are printed onto a print foundation retained by the additive manufacturing system, and wherein the method further comprises indexing the print foundation along the printing axis.

5. The method of claim 4, and further comprising:

engaging the print foundation with a drive mechanism of the additive manufacturing system, wherein indexing the print foundation is performed by the drive mechanism; and

engaging the scaffold with the drive mechanism to index the scaffold along the printing axis after indexing the print foundation.

6. The method of claim 4, and further comprising printing a support structure onto the print foundation in a layer-by-layer manner along the printing axis prior to printing the three-dimensional part.

7. The method of claim 1, and further comprising removing the scaffold from the three-dimensional part after completing the printing of the three-dimensional part.

8. The method of claim 1, wherein the printing axis is a horizontal axis.

9. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:

extruding a layer of a scaffold with a sacrificial material onto a print foundation retained by the additive manufacturing system, along a substantially horizontal printing axis and a substantially vertical print plane wherein the scaffold comprises;

a ribbon portion having a wave pattern; and

a base connected to the ribbon portion opposite of the three-dimensional part;

extruding a layer of the three-dimensional part onto the print foundation along with the printing of the layer of the scaffold such that the layer of the scaffold is connected to the layer of the three-dimensional part at one or more tangential locations of the ribbon portion, the locations providing periodic contact points spaced from one another a selected distance to address forces parallel to a build plane to reduce or prevent the three-dimensional part from sagging laterally relative to the horizontal printing axis while printing an additional portion of the three-dimensional part; and

indexing the scaffold and the three-dimensional part along the printing axis.

10. The method of claim 9, and further comprising resting at least a portion of the conveyor base on a surface of the additive manufacturing system.

11. The method of claim 9, and further comprising:

engaging the conveyor base with a drive mechanism of the additive manufacturing system; and

indexing the scaffold along the horizontal printing axis with the engaged drive mechanism.

12. The method of claim 9, and further comprising printing a support structure onto the print foundation in a layer-by-layer manner along the horizontal printing axis prior to printing the scaffold and the three-dimensional part.

13. The method of claim 9, wherein the layer of the scaffold has one or more walls that are each about one road-width thick.

14. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:

printing a scaffold with a sacrificial material in a build plane onto a print foundation retained by the additive manufacturing system, along a substantially vertical printing axis, wherein the scaffold comprises;

a ribbon portion having a wave pattern; and

printing the three-dimensional part in the build plane onto the print foundation along with printing the scaffold such that the scaffold is laterally connected to the three-dimensional part at a plurality of contact points positioned at spaced apart tangential locations on the ribbon portion and the three-dimensional part to address forces parallel to the build plane to reduce or prevent the three-dimensional part from wobbling relative to the vertical printing axis while printing an additional portion of the three-dimensional part and wherein the scaffold is configured for breaking away from the printed three-dimensional part at the plurality of contact points; and

indexing the scaffold and the three-dimensional part along the vertical printing axis with the engaged drive mechanism.

15. The method of claim 14, wherein the scaffold further comprises a conveyor base connected to the ribbon portion opposite of the three-dimensional part.

16. The method of claim 15, and further comprising:

engaging the conveyor base with a drive mechanism of the additive manufacturing system; and

indexing the scaffold along the horizontal printing axis with the engaged drive mechanism.

17. The method of claim 14, and further comprising printing a support structure onto the print foundation in a layer-by-layer manner along the vertical printing axis prior to printing the scaffold and the three-dimensional part.