Three-dimensional printer having an expandable envelope

• US 9,724,878 B2
• Filed: 10/20/2014
• Issued: 08/08/2017
• Est. Priority Date: 10/20/2014
• Status: Active Grant

• Current Assignee: Lenovo Global Technologies International Ltd. (Lenovo Group Ltd.)
• Original Assignee: Lenovo Enterprise Solutions (Singapore) Pte., Ltd. (Lenovo Group Ltd.)
• Inventors: Davis, Alvin G., Ruggles, April E., Wormsbecher, Paul A., Megarity, William M.
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US14/518,405
• Publication Number:
  US 20160107390A1
• Time in Patent Office: 1,023 Days
• CPC Class Codes: B25J 9/0096 co-operating with a working support, e.g. work-table
• CPC Class Codes: B25J 9/026 Gantry-type
• 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 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/232 for motion along the axis orthogonal to the plane of a layer
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/245 Platforms or substrates support structures intended to be sacrificed after manufacture B29C64/40
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B62D 57/032 with alternately or sequentially lifted supporting base and legs; with alternately or sequentially lifted feet or skid B62D57/024 takes precedence
• CPC Class Codes: G05B 15/02 electric

Abstract

A computer program product includes a computer readable storage medium having program instructions embodied therewith and executable by a processor to cause the processor to perform a method. The method includes a three-dimensional printer printing a first layer of an object onto a surface that is not part of the three-dimensional printer, wherein the first layer is printed while a printing platform of the three dimensional printer is in a first position. The printer is autonomously repositioned in a second position elevated above the first position by being supported either on the three-dimensional object itself or on a scaffold printed separate from the object. The printer prints a second layer of the three-dimensional object onto the first layer of the three-dimensional object while the printing platform is in the second position. The printer may have a plurality of legs for controllably repositioning the printing platform.

Claims

1. A computer program product comprising a computer readable storage medium that is not a transitory signal having program instructions embodied therewith, the program instructions executable by a processor to:

print, using a three-dimensional printer, a first layer of a three-dimensional object onto a surface that is not part of the three-dimensional printer, wherein the first layer is printed while a printing platform of the three dimensional printer is in a first position;

print, using the three-dimensional printer, a first layer of a scaffold separate from the first layer of the three-dimensional object;

autonomously reposition the three-dimensional printer to be supported on the scaffold in a second position elevated above the first position; and

print, using the three-dimensional printer, a second layer of the three-dimensional object onto the first layer of the three-dimensional object while the printing platform is in the second position.

2. The computer program product of claim 1, wherein the scaffold is printed around the perimeter of the three-dimensional object.

3. The computer program product of claim 1, wherein the three-dimensional printer includes a plurality of legs secured to the printing platform.

4. The computer program product of claim 3, wherein the plurality of legs include a first subset of at least three legs and a second subset of at least three legs.

5. The computer program product of claim 4, wherein the scaffold includes a separate scaffold structure associated with each of the plurality of legs.

6. The computer program product of claim 4, wherein the scaffold includes a first subset of scaffold structures associated with the first subset of legs and a second subset of scaffold structures associated with the second subset of legs.

7. The computer program product of claim 6, wherein the program instructions executable by the processor to autonomously reposition the three-dimensional printer to be supported on the scaffold in a second position elevated above the first position, includes program instructions executable by the processor to:

support the printing platform on the second subset of legs;

articulate the first subset of the legs to engage the first subset of scaffold structures and support the printing platform in the first position while the first layer of the second subset of scaffold structures is printed;

articulate the second subset of the legs to engage the second subset of scaffold structures and support the printing platform in the first position; and

articulate the first subset of the legs to lift the printing platform from the first position to the second position.

8. The computer program product of claim 6, wherein the program instructions executable by the processor to autonomously reposition the three-dimensional printer to be supported on the scaffold in a second position elevated above the first position, includes program instructions executable by the processor to:

support the printing platform on the second subset of legs; and

articulate the first subset of the legs to engage the first subset of scaffold structures and lift the printing platform to the second position before the first layer of the second subset of scaffold structures is printed.

9. The computer program product of claim 1, the program instructions further executable by the processor to:

print, using the three-dimensional printer while the printing platform is in the second position, a second layer of the three-dimensional object over the first layer of the three-dimensional object and a second layer of the scaffold over the first layer of the scaffold.

10. The computer program product of claim 7, the program instructions further executable by the processor to:

move the first subset of the legs out of alignment with the first subset of scaffold structures to allow printing a second layer of the first subset of scaffold structures on the first layer of the first subset of scaffold structures; and

move the second subset of the legs out of alignment with the second subset of scaffold structures to allow printing a second layer of the second subset of scaffold structures on the first layer of the second subset of scaffold structures.

11. The computer program product of claim 3, wherein each leg includes a scaffold print head for printing a scaffold structure to support the leg.

12. The computer program product of claim 11, wherein the scaffold print head prints the scaffold structure outside the range of the object print head.

13. The computer program product of claim 11, wherein the scaffold print heads included with the first subset of legs print scaffold structures simultaneously, and wherein the scaffold print heads included with the second subset of legs print scaffold structures simultaneously.

14. The computer program product of claim 11, wherein the program instructions executable by the processor to print a first layer of the three-dimensional object while the printer is supported on the first subset of scaffolds, includes program instructions executable by the processor to print multiple layers of the three-dimensional object while the printer is supported on the first subset of scaffolds at a particular elevation;

and

wherein the program instructions executable by the processor to print a second layer over the first layer of the three-dimensional object while the printer is supported on the second subset of scaffolds, includes program instructions executable by the processor to print multiple layers of the three-dimensional object while the printer is supported on the second subset of scaffolds at a particular elevation.

15. The computer program product of claim 14, wherein the program instructions executable by the processor to print the second layer of the second subset of the scaffold structures, includes program instructions executable by the processor to print multiple layers on the second subset of scaffold structures while the three-dimensional printer is supported on the first subset of scaffolds at a particular elevation;

and

wherein the program instructions executable by the processor to print the second layer of the first subset of the scaffold structures, includes program instructions executable by the processor to print multiple layers on the first layer of the first subset of scaffold structures while the three-dimensional printer is supported on the second subset of scaffolds at the particular elevation.

16. The computer program product of claim 1, the program instructions further executable by the processor to:

optically scan the three-dimensional object after the three-dimensional printer is supported in the second position; and

adjust printing instructions for printing the second layer of the three-dimensional object after the three-dimensional printer is supported in the second position to account for changes in alignment of the printer relative to the three-dimensional object.

17. A computer program product comprising a computer readable storage medium that is not a transitory signal having program instructions embodied therewith, the program instructions executable by a processor to:

print, using a three-dimensional printer, a first layer of a three-dimensional object onto a surface that is not part of the three-dimensional printer, wherein the first layer is printed while a printing platform of the three dimensional printer is in a first position;

autonomously reposition the printing platform of the three-dimensional printer to be supported on the three-dimensional object in a second position elevated above the first position; and

print, using the three-dimensional printer, a second layer of the three-dimensional object on the first layer of the three-dimensional object while the printing platform of the three-dimensional printer is in the second position.

18. The computer program product of claim 17, the program instructions further executable by the processor to:

modify print instructions for the three-dimensional object to reinforce the strength of regions of the three-dimensional object that will support the three-dimensional printer.

19. The computer program product of claim 17, wherein the program instructions executable by the processor to autonomously reposition the printing platform of the three-dimensional printer to be supported on the three-dimensional object in a second position elevated above the first position, includes program instructions executable by the processor to:

support, on a second subset of at least three legs, the printing platform on the surface that is not part of the three-dimensional printer; and

articulate a first subset of the legs to engage the first layer of the three dimensional object and support the printing platform while the second layer of the three-dimensional object is printed.

20. The computer program product of claim 19, the program instructions further executable by the processor to:

articulate the second subset of the legs to engage the second layer of the three-dimensional object and support the printing platform;

articulate the first subset of the legs out of alignment with a region of the three-dimensional object where the first subset of the legs engaged the three-dimensional object; and

print in the region to complete the second layer of the three-dimensional object.