METHOD FOR PRINTING A THREE-DIMENSIONAL STRUCTURE, METHOD FOR CONTROLLING A PRINT HEAD AND A PRINTED ARTICLE

• US 20150093552A1
• Filed: 04/29/2013
• Published: 04/02/2015
• Est. Priority Date: 05/07/2012
• Status: Active Grant

• Current Assignee: META Platforms Technologies LLC (Meta Platforms, Inc. (f/k/a Facebook, Inc.))
• Original Assignee: LUXeXceL Holding B.V.
• Inventors: Biskop, Joris, Van De Vrie, Richard
• Granted Patent: US 10,556,417 B2
• Time in Patent Office: Days
• US Class Current: 428/201
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• 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: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2101/00 Use of unspecified macromolecular compounds as moulding material use of unspecified rubbers B29K2021/00
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential

Abstract

The present invention relates to a method for printing a three-dimensional structure comprising the steps of providing structural parameters defining the shape of the three-dimensional structure in a first step, converting the structural parameters into an intensity image having multiple pixels which are arranged in a two-dimensional pattern and which comprises at least different intensities in a second step and controlling the print head in dependency of the intensity image in order to print the three-dimensional structure in a third step, wherein the print head moves to a certain position and deposits at least one droplet of printing material when processing a certain pixel and wherein the number of droplets and/or the amount of printing material deposited at the certain position by the print head is chosen in dependency of the intensity of the corresponding pixel.

Claims

1. A method for printing a three-dimensional structure comprising the following steps:

1) providing structural parameters defining the shape of the three-dimensional structure in a first step;

2) converting the structural parameters into an intensity image having multiple pixels which are arranged in a two-dimensional pattern and which comprises at least different intensities in a second step;

wherein the structural parameters are converted into a colored intensity image having multiple pixels which comprises different colors in the second step,

wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that each pixel represents a certain position in an orthogonal projection of the three-dimensional structure,

wherein the color of each pixel represents geometrical, optical and/or visual characteristics of the three-dimensional structure at this position,

wherein the intensity of each pixel represents the height of the three-dimensional structure at this position;

3) controlling the print head in dependency of the intensity image in order to print the three-dimensional structure in a third step,

wherein the print head moves to a certain position and deposits at least one droplet of printing material when processing a certain pixel,

wherein the number of droplets and/or the amount of printing material deposited at the certain position by the print head is chosen in dependency of the intensity of the corresponding pixel.

2. The method according to claim 1, wherein the structural parameters are converted into a colored intensity image having multiple pixels which comprises different colors in the second step and

wherein the print head is controlled in dependency of the colored intensity image in order to print the three-dimensional structure in a third step, and

wherein the type of printing material deposited at the certain position by the print head is chosen in dependency of the color of the corresponding pixel.

3. The method according to claim 1, wherein the structural parameters are provided as CAD-data in the first step.

4. The method according to claim 1, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that

a certain color of a pixel represents a certain kind of UV light to be used for curing the droplets deposited at the corresponding position,

wherein the print head deposits droplets of printing material at a certain position in the third step and

wherein a light source cures the deposited droplet when the corresponding pixel comprises a color representing the kind of UV light emitted by the light source.

12. The method according to claim 4, wherein the color represents a certain wavelength spectrum of the UV light and the light source cures the deposited droplet with light of a certain wavelength spectrum when the corresponding pixel comprises a color representing this wavelength spectrum.

13. The method according to claim 1, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that another certain color of a pixel represents a finishing material,

wherein the method comprises a fourth step, in which the print head deposits droplets of the finishing material at a certain position onto the three-dimensional structure printed in the third step when the corresponding pixel comprises a color representing the finishing layer.

14. The method according to claim 1, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that a certain color of a pixel represents a support material for providing overhanging areas in the three-dimensional structure,

wherein the print head deposits droplets of the support material at a certain position in the third step when the corresponding pixel comprises a color representing the support material layer, and

wherein the method comprises a fifth step, in which the deposited support material is removed to generate the overhanging areas.

15. The method according to claim 14, wherein the support material is dissolved with a water-based dissolution in the fifth step.

16. The method for controlling a print head of an inkjet printer, for performing a method according to claim 1.

17. A printed article comprising a three-dimensional structure printed by a method according to claim 1.

18. The method according to claim 2, wherein the structural parameters are provided as CAD-data in the first step.

19. The method according to claim 2, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that

a certain color of a pixel represents a certain kind of UV light to be used for curing the droplets deposited at the corresponding position,

wherein the print head deposits droplets of printing material at a certain position in the third step and

wherein a light source cures the deposited droplet when the corresponding pixel comprises a color representing the kind of UV light emitted by the light source.

20. The method according to claim 3, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that

a certain color of a pixel represents a certain kind of UV light to be used for curing the droplets deposited at the corresponding position,

wherein the print head deposits droplets of printing material at a certain position in the third step and

wherein a light source cures the deposited droplet when the corresponding pixel comprises a color representing the kind of UV light emitted by the light source.

21. The method according to claim 2, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that another certain color of a pixel represents a finishing material,

wherein the method comprises a fourth step, in which the print head deposits droplets of the finishing material at a certain position onto the three-dimensional structure printed in the third step when the corresponding pixel comprises a color representing the finishing layer.

22. The method according to claim 12, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that another certain color of a pixel represents a finishing material,

wherein the method comprises a fourth step, in which the print head deposits droplets of the finishing material at a certain position onto the three-dimensional structure printed in the third step when the corresponding pixel comprises a color representing the finishing layer.

23. The method according to claim 20, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that another certain color of a pixel represents a finishing material,

wherein the method comprises a fourth step, in which the print head deposits droplets of the finishing material at a certain position onto the three-dimensional structure printed in the third step when the corresponding pixel comprises a color representing the finishing layer.

24. The method according to claim 2, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that a certain color of a pixel represents a support material for providing overhanging areas in the three-dimensional structure,

wherein the print head deposits droplets of the support material at a certain position in the third step when the corresponding pixel comprises a color representing the support material layer, and

wherein the method comprises a fifth step, in which the deposited support material is removed to generate the overhanging areas.

25. The method according to claim 23, wherein the structural parameters are converted into the colored intensity image in the second step in such a manner that a certain color of a pixel represents a support material for providing overhanging areas in the three-dimensional structure,

wherein the print head deposits droplets of the support material at a certain position in the third step when the corresponding pixel comprises a color representing the support material layer, and

wherein the method comprises a fifth step, in which the deposited support material is removed to generate the overhanging areas.

26. The method according to claim 25, wherein the support material is dissolved with a water-based dissolution in the fifth step.

27. The method for controlling a print head of an inkjet printer, for performing a method according to claim 25.

5-11. -11. (canceled)