Apparatus and method for forming three-dimensional objects from solidifiable paste

• US 9,527,244 B2
• Filed: 02/10/2014
• Issued: 12/27/2016
• Est. Priority Date: 02/10/2014
• Status: Active Grant

• Current Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Original Assignee: Gulf Filtration Systems Inc. (Desktop Metal, Inc.)
• Inventors: El-Siblani, Ali
• Primary Examiner(s): SANDERS, JAMES M
• Application Number:
  US14/176,792
• Publication Number:
  US 20150224710A1
• Time in Patent Office: 1,051 Days
• US Class Current: 1/1
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/214 Doctor blades
• CPC Class Codes: B29C 64/241 for rotary motion
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29L 2009/00 Layered products
• 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 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

Abstract

An apparatus and method for making a three-dimensional object from a solidifiable paste is shown and described. The apparatus includes a pastes spreader, at least a portion of which extends into the solidifiable paste. The container holding the solidifiable paste and the spreader are movable relative to one another. In one system, the spreader vibrates as the container and the spreader move relative to one another. In another system, the spreader is part of a spreader assembly in which a first spreader and second spreader are angled with respect to one another, and the assembly is rotatable and lockable into multiple rotational positions. The apparatus and method allow three-dimensional objects to be progressively built upside down by ensuring that the previously solidified object section has a substantially homogeneous layer of solidifiable material available for forming a new layer of the solidified object prior to exposure to solidification energy.

Claims

1. An apparatus for supplying a solidifiable paste that solidifies when exposed to solidification energy, the apparatus comprising:

a solidifiable paste container comprising an open top and a closed bottom, wherein the container has a height, a cross-sectional area perpendicular to the height, and an interior volume for holding the solidifiable paste;

a spreader having a length defining a first axis, wherein the length of the spreader is located within the cross-sectional area, at least a portion of the spreader extends into the interior volume, and at least one of the spreader and the solidifiable paste container is movable relative to the other of the spreader and the solidifiable paste container while the portion of the spreader extends into the interior volume;

wherein the spreader is a first spreader, the apparatus further comprises a second spreader, the second spreader has a length along the first axis, at least a portion of the second spreader extends into the interior volume, and at least one of the second spreader and the solidifiable paste container is movable relative to the other of the second spreader and the solidifiable paste container while the at least a portion of the second spreader extends into the interior volume; and

the apparatus further comprises a spreader assembly comprising the first spreader and the second spreader, wherein the spreader assembly is rotatable about an axis of rotation parallel to the first axis.

2. The apparatus of claim 1, wherein the container has walls defining the open top, the spreader has ends spaced apart from one another along the first axis, and the ends are spaced apart from the container walls along the first axis.

3. The apparatus of claim 1, wherein the spreader is pivotable about a pivot axis parallel to the first axis to a selected angle relative to the container.

4. The apparatus of claim 1, wherein the spreader is a blade having a leading edge, the leading edge extends into the interior volume, and the leading edge has a plurality of gaps along the first axis.

5. The apparatus of claim 1, wherein the spreader is a blade having a leading edge and the leading edge is spaced apart from the closed bottom of the container by an adjustable distance.

6. The apparatus of claim 1, wherein the spreader is vibratable while the spreader and the solidifiable paste container move relative to one another.

7. The apparatus of claim 1, wherein the spreader is translatable relative to the solidifiable paste container across the cross-sectional area.

8. The apparatus of claim 1, wherein the solidifiable paste container is rotatable relative to the spreader.

9. The apparatus of claim 8, wherein the solidifiable paste container is rotatable by at least about 180 degrees.

10. The apparatus of claim 1, wherein the first spreader and the second spreader have a fixed angular orientation relative to one another when viewed along the first axis.

11. The apparatus of claim 1, further comprising a lock, wherein the lock releasably secures the spreader assembly in a select one of a plurality of rotational positions about the axis of rotation.

12. The apparatus of claim 11, wherein in a first rotational position, a height dimension of the first spreader is oriented perpendicularly to the closed bottom of the solidifiable paste container and a height dimension of the second spreader is oriented at an angle relative to the closed bottom of the solidifiable paste container.

13. The apparatus of claim 11, wherein during a paste spreading operation, the first spreader engages a wall of the solidifiable paste container or at least one hard stop to adjust the rotational position of the spreader assembly from a first rotational position about the axis of rotation to a second rotational position about the axis of rotation.

14. The apparatus of claim 1, wherein the first and second spreaders each have serrated leading edges.

15. The apparatus of claim 1, wherein the cross-sectional area is circular.

16. The apparatus of claim 1, wherein the cross-sectional area is rectangular.

17. The apparatus of claim 1, wherein the closed bottom of the solidifiable paste container is transparent and/or translucent.

18. The apparatus of claim 1, wherein the extent to which the spreader extends into the interior volume defines a depth of penetration into the interior volume, and the depth of penetration is adjustable.

19. The apparatus of claim 1, further comprising a motor operatively connected to the spreader such that when the motor is energized, the spreader moves relative to the container along a second axis, and a controller programmed to selectively energize the motor.