WO2017023281A1 - Imprimante 3d à multiples chariots - Google Patents

Imprimante 3d à multiples chariots Download PDF

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Publication number
WO2017023281A1
WO2017023281A1 PCT/US2015/043289 US2015043289W WO2017023281A1 WO 2017023281 A1 WO2017023281 A1 WO 2017023281A1 US 2015043289 W US2015043289 W US 2015043289W WO 2017023281 A1 WO2017023281 A1 WO 2017023281A1
Authority
WO
WIPO (PCT)
Prior art keywords
carriage
build material
print bed
material layer
over
Prior art date
Application number
PCT/US2015/043289
Other languages
English (en)
Inventor
Wesley R. Schalk
Matthew A. Shepherd
Original Assignee
Hewlett-Packard Development Company, L.P.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hewlett-Packard Development Company, L.P. filed Critical Hewlett-Packard Development Company, L.P.
Priority to PCT/US2015/043289 priority Critical patent/WO2017023281A1/fr
Publication of WO2017023281A1 publication Critical patent/WO2017023281A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

Definitions

  • 3D printers often use an inkjet type printhead to deliver a liquid or colloidal binder material to layers of build material in powder form.
  • the printing process typically includes applying a layer of build material to a surface and delivering the liquid binder material to predetermined areas of the build material layer.
  • the liquid binder material infiltrates the build material and reacts with the build material, causing the build material layer to solidify in the printed areas by, for example, activating an adhesive.
  • areas of the build material layer that have received the liquid fuse together through application of heat onto the build material layer.
  • FIGS. 1 -3 are a simplified block diagrams of a three dimensional (3D) printer for generating, building, or printing three-dimensional parts, according to examples of the present disclosure
  • FIGS. 4 and 5 respectively, show flow diagrams of methods for operating a 3D printer to form a 3D object, according to two examples of the present disclosure.
  • FIG. 6 is schematic representation of a management apparatus, which may be equivalent to the management apparatus depicted in FIG. 3, according to an example of the present disclosure.
  • the 3D printers disclosed herein may include a print bed on which a 3D object is to be printed, formed, or otherwise generated.
  • the 3D printers disclosed herein may also include a first carriage and a second carriage that are to be moved over or across the print bed to enable components included in the first carriage and the second carriage to perform various operations during formation of a 3D object.
  • the first carriage and the second carriage are independently movable over the print bed and are to move along the same axis with respect to each other. The independent movement may enable the first carriage and the second carriage to move synchronously or asynchronously with respect to each other.
  • a build material spreader may be mounted on the first carriage such that the spreader may spread a build material over the print bed as the first carriage is moved over the print bed.
  • a printhead may be positioned on the second carriage, in which the printhead is to deposit a fluid over the spread build material.
  • the fluid may be deposited at on the spread build material in a controlled manner, i.e., at desired locations of the spread build material, to thus enable a desired pattern to be formed on the spread build material.
  • the spreader and the printhead may be contained on separate carriages to reduce or minimize dust and/or heat from the build material from affecting the printhead.
  • 3D parts or objects may be formed in a relatively efficient manner.
  • the 3D parts or objects may be formed with a relatively high level of flexibility as provided through the independent movement of the first carriage with respect to the second carriage.
  • the 3D printers disclosed herein may include a third carriage that is independently movable with respect to the first carriage and the second carriage.
  • the third carriage may also include a printhead such that the printheads in the second carriage and the third carriage may alternatively deposit fluid onto respective build material layers, which may increase efficiency, e.g., decrease the amount time required, in forming 3D parts or objects.
  • the third carriage may additionally or alternatively include a spreader and/or an energy source.
  • FIG. 1 there is shown a simplified block diagram of a three dimensional (3D) printer 100 for generating, building, or printing three-dimensional parts, according to an example.
  • the 3D printer 100 depicted in FIG. 1 may include additional components and that some of the components described herein may be removed and/or modified without departing from a scope of the 3D printer 100 disclosed herein.
  • the 3D printer 100 depicted in FIG. 1 may not be drawn to scale and thus, the 3D printer 100 may have a different size and/or configuration other than as shown therein.
  • the 3D printer 100 is depicted as including a print bed 102, which may be positioned on a platform (not shown) that is to move in a vertical direction to thus cause the print bed 102 to move in a vertical direction as represented by an arrow 104.
  • 3D objects or parts are to be generated from a build material 106.
  • the 3D objects or parts are to be generated within a build envelope, which may be defined as the three-dimensional space on top of the print bed 102, of the 3D printer 100.
  • the build envelope may be defined as the three-dimensional space in which the 3D printer 100 may print or otherwise generate the 3D parts.
  • the width and the length of the build envelope may be limited by the width and the length of the print bed 102 and the height of the build envelope may be limited by the extent to which the print bed 102 may be moved vertically.
  • an actuator such as a piston, may move the print bed 102 vertically as represented by the arrow 104.
  • the build material 106 may be contained in a hopper or other build material source 108 and may be applied or spread as desired onto the print bed 102 by a spreader 1 10 to form a build material layer 1 12.
  • the build material 106 may be provided at the build material source 108 at a slightly higher elevation as compared to the height of the surface of the print bed 102 and the spreader 1 10 may move in a horizontal direction from a location above the build material source 108 to a location across the print bed 102 from the build material source 108, as represented by the arrow 1 14.
  • the build material source 108 may include a mechanism to provide, e.g., move, the build material layer 1 12 from a storage location to a position to be spread onto the print bed 102 or a previously formed build material layer.
  • the spreader 1 10 may be positioned above the print bed 102 such that a relatively small gap exists between the spreader 1 10 and the print bed 102.
  • a layer of the build material 1 12 may be formed on the print bed 102.
  • a similar operation may be performed to form additional build material layers above the print bed 102.
  • the spreader 1 10 may be a doctor blade or any other device suitable for spreading the build material 106 over the print bed 102.
  • the spreader 1 10 may be a counter rotating roller.
  • the spreader 1 10 may be mounted on a first carriage 1 16, in which the first carriage 1 16 is to be moved across the print bed 102.
  • the first carriage 1 16 may be movably supported on a rail 1 18 and the first carriage 1 16 may be moved along the rail 1 18 such that the spreader 1 10 may be moved from a location above the build material source 108 to an opposite end of the print bed 102.
  • the 3D printer 100 includes a second carriage 120 on which is mounted a printhead (PH) 122.
  • the printhead 122 may include a plurality of nozzles (not shown) through which a fluid, such as ink, water, or the like, is to be ejected.
  • the printhead 122 may be, for instance, a thermal inkjet printhead, a piezoelectric printhead, etc., and may extend a width of the print bed 102.
  • the second carriage 120 may be moved across the print bed 102 in the horizontal direction as represented by the arrow 124 to enable the printhead 122 to deposit fluid onto desired locations of the build material layer 1 12 through the nozzles.
  • the second carriage 120 has been depicted in FIG. 1 as including a single printhead 122, it should be understood that the second carriage 120 may support any reasonably suitable number of printheads in an array, in which the printheads are to deposit either one type of fluid or multiple types of fluids.
  • the printhead 122 may be controlled to deposit the fluid at the locations on the build material layer 1 12 that are to be fused together or otherwise solidified.
  • the 3D printer 100 may further include an energy source that is to apply energy, e.g., heat, onto the build material layer 1 12 and the deposited fluid to cause the sections of the build material 106 upon which the fluid has been deposited to be fused together.
  • the printhead 122 may deposit an energy absorbing ink onto the desired locations of the build material layer 1 12 and the application of energy onto the build material layer 1 12 and the energy absorbing ink may cause the build material 106 upon which the energy absorbing ink has been deposited to reach a higher temperature than other sections of the build material 106.
  • the higher temperature may cause the build material 106 that has received the energy absorbing ink to fuse together without causing the other sections of the build material 106 from fusing together.
  • another printhead may deposit another liquid onto sections of the build material layer 1 12 that are adjacent to the sections that have received the energy absorbing ink to limit or reduce the amount of heat transferred from the sections that have received the energy absorbing ink to neighboring sections of the build material layer 1 12. The another liquid may thus be used to enhance control over the fusing of the sections of the build material 106.
  • the second carriage 120 is independently movable with respect to the first carriage 1 16 and may be movable in-line, e.g., along the same axis, as the first carriage 1 16. That is, for instance, the second carriage 120 may remain stationary as the first carriage 1 16 is moving across the print bed 102 and vice versa. In another example, both the first carriage 1 16 and the second carriage 120 may concurrently move in the same direction across the print bed 102, but the first carriage 1 16 may be moved at a different speed as compared with the movement of the second carriage 120. In a further example, the first carriage 1 16 may be moved in one direction while the second carriage 120 is concurrently moved in an opposite direction. In this regard, the first carriage 1 16 and the second carriage 120 may be moved synchronously or asynchronously with respect to each other.
  • the 3D printer 100 may include a controller 130, which may be a computing device, a semiconductor-based microprocessor, an application specific integrated circuit (ASIC), and/or other hardware device that is to control operations of various components in the 3D printer 100.
  • the communication lines between the controller 130 and other components of the 3D printer 100 are depicted as dashed lines.
  • the controller 130 may independently control a first drive system 140 and a second drive system 142 to independently control the movement and/or the speeds of movement of the first carriage 1 16 and the second carriage 120.
  • the first drive system 140 may include a first belt and pulley system attached to the first carriage 1 16, in which the belt is attached to a first motor, which the controller 130 may control.
  • the second drive system 142 may include a second belt and pulley system attached to the second carriage 120, in which the belt is attached to a second motor, which the controller 130 may control.
  • the independently controllable drive systems 140 and 142 enable the first carriage 1 16 to be independently movable with respect to the second carriage 120. It should be understood that the first drive system 140 and the second drive system 142 may include drive systems other than belt and pulley systems without departing from a scope of the present disclosure.
  • the controller 130 is also depicted as being in communication with a data store 132.
  • the data store 132 may include data pertaining to a 3D part to be printed by the 3D printer 100.
  • the data may include the locations in each build material layer 1 12 that the printhead 122 is to deposit ink to form the 3D part.
  • the controller 130 may use the data to control the locations on each of the build material layers 1 12 that the printhead 122 deposits fluid.
  • the controller 130 may also control the supply of build material 106 by the build material source 108, the movement of the print bed 102, the movement of the spreader 1 10, etc., as described in greater detail herein below.
  • the first carriage 1 16 and the second carriage 120 are movably mounted on the rail 1 18.
  • the first carriage 1 16 and the second carriage 120 are movable in-line with each other, i.e., along the axis of the rail 1 18.
  • the 3D printer 100 may include a second rail (not shown) that is positioned parallel to the rail 1 18 to thus enable a carriage that is mounted on the second rail to also move over the print bed 102.
  • the first carriage 1 16 may be movably mounted to the rail 1 18 and the second carriage 120 may be movably mounted to the second rail while still being movable over the print bed 102 in-line with respect to each other.
  • the controller 130 may control the first drive system 140 to move the first carriage 1 16 across the print bed 102 in a direction toward the second carriage 120 to form a build material layer 1 12 over the print bed 102.
  • the first carriage 1 16 may then be moved in an opposite direction away from the second carriage 120 and the second carriage 120 may also move in that direction to move the printhead 122 across the formed build material layer 1 12.
  • the controller 130 may control the printhead 122 to deposit a fluid onto desired, e.g., predetermined, locations of the build material layer 1 12.
  • the second carriage 120 may be moved in a direction away from the first carriage 1 16 along the rail 1 18.
  • the printhead 122 may deposit additional fluid onto the build material layer 1 12 either onto the previously deposited locations or to new locations on the build material layer 1 12.
  • the printhead 122 may not deposit additional fluid during this movement and may simply move to get out of the way of the first carriage 1 16. Following deposition of the fluid during a first pass and/or second pass in an opposite direction of the first pass of the printhead 122 over the build material layer 1 12, energy may be applied onto the build material layer 1 12 to fuse the desired sections of the build material layer 1 12 together as described in greater detail herein below.
  • the controller 130 may then control the print bed 102 to be moved in a downward direction as represented by the arrow 104.
  • the print bed 102 may be lowered a distance that is equivalent to the height of the build material layer 1 12, for instance, about 100 microns.
  • a second build material layer (not shown) may be formed on top of the previously formed build material layer 1 12. That is, the first carriage 1 16 may be positioned over the build material source 108 and additional build material 106 may be provided between the spreader 1 10 and the print bed 102.
  • the first carriage 1 16 may be moved across the print bed 102 to thus cause the additional build material 106 to be spread over the previously formed build material layer 1 12 and form a second build material layer on top of the previously formed build material layer 1 12.
  • the first carriage 1 16 may be moved back over the build material source 108 and the second carriage 120 may be moved across the second build material layer to thus enable the printhead 122 to deposit fluid onto desired, e.g., predetermined, locations on the second build material layer.
  • the fluid may be deposited on the same or different locations on the second build material layer as compared with the previously formed build material layer 1 12.
  • the second carriage 120 may then be moved back away from the first carriage 1 16 and this entire process may be repeated for additional build material layers as needed to form a desired 3D part or object.
  • the build material 106 is a powder-based build material.
  • powder-based build material is intended to encompass dry powder-based materials, wet powder-based materials, particulate materials, granular materials, etc.
  • the build material 106 may be used with other suitable build materials, with suitable modification if appropriate.
  • the build material 106 may be any other suitable form of build material.
  • the build material 106 is a powdered thermoplastic material.
  • One suitable material may be Nylon 12, which is available, for example, from Sigma-Aldrich Co, LLC.
  • Another suitable material may be PA2200, which is available from Electro Optical Systems EOS GmbH.
  • the build material 106 may include, for example, powdered metal materials, powdered composited materials, powder ceramic materials, powdered glass materials, powdered resin material, powdered polymer materials, and the like.
  • the build material 106 may be a liquid, a paste, or a gel.
  • the build material 106 include polymeric semi-crystalline plastic materials with a wide processing window of greater than 5°C (i.e., the temperature range between the melting point and the re-crystallization temperature). In an example, the processing window ranges from 15°C to about 30°C.
  • suitable build materials 106 may include polyamides, polyethylene, polyethylene terephthalate (PET), and amorphous variations of these materials.
  • suitable build materials 106 may include polystyrene, polyacetals, polypropylene, polycarbonate, polyester, polyurethanes, other engineering plastics, and blends of any two or more of the polymers listed herein. Core shell polymer particles of these materials may also be used.
  • the build material 106 may have a melting point ranging from about 55°C to about 450°C. Some specific examples of the build material 106 having their melting point within this range include polyamides, such as nylon 1 1 , nylon 12, nylon 6, nylon 8, nylon 9, nylon 66, nylon 612, nylon 812, nylon 912, etc. As examples, polyamide 12 has a melting point of about 180°, polyamide 6 has a melting point of about 220°, and polyamide 1 1 has a melting point of about 200°.
  • the build material 106 may also be a modified polyamide. In an example, the modified polyamide material is an elastomeric modified polyamide that melts at a lower temperature than nylon 12.
  • FIG. 2 there is shown a simplified block diagram of a 3D printer 200, according to an example.
  • the 3D printer 200 depicted in FIG. 2 may include additional components and that some of the components described herein may be removed and/or modified without departing from a scope of the 3D printer 200 disclosed herein.
  • the 3D printer 200 depicted in FIG. 2 may not be drawn to scale and thus, the 3D printer 200 may have a different size and/or configuration other than as shown therein.
  • the 3D printer 200 depicted in FIG. 2 includes many of the same elements as those included in the 3D printer 100 depicted in FIG. 1 . As such, the features in the 3D printer 200 that are common to the features in the 3D printer 100 will not be described in detail other than to provide a description of how those features operate in the context of the 3D printer 200. Instead, the descriptions of the common features provided above with respect to the 3D printer 100 are intended to also describe the common features contained in the 3D printer 200.
  • the 3D printer 200 depicted in FIG. 2 differs from the 3D printer 100 depicted in FIG. 1 in that the 3D printer 200 is depicted as including features in addition to the features contained in the 3D printer 100 depicted in FIG. 1 .
  • Two of the additional features are energy sources 202 and 204, which may be lamps or other sources of energy, e.g., light, heat, or the like. In an example, either or both of the energy sources 202 and 204 may apply energy onto the build material layer 1 12 as the first carriage 1 16 is moved over the build material layer 1 12 to maintain the build material 106 within a predetermined temperature range and/or to fuse sections of the build material layer 1 12 together.
  • the amount of energy applied to the build material layer 1 12 may be controlled, for instance, by controlling the speed at which the first carriage 1 16 is moved over the build material layer 1 12.
  • the controller 130 is to control at least one of the intensity and the wavelength of light emitted from the energy sources 202 and 204 to therefore vary the amount of energy being applied to the build material layer 1 12.
  • the predetermined temperature range at which the build material 106 is to be maintained may depend upon the type of the build material 106 and may be specified by a manufacturer of the build material 106.
  • the predetermined temperature range of the build material 106 may be a temperature range at which the build material 106 exhibits desired properties during fusing of sections of the build material layer 1 12.
  • the energy sources 202 and 204 may also be moved over the build material source 108 to apply energy onto the build material 106 contained in the build material source 108. Energy may be applied onto the build material 106 contained in the build material source 108 to maintain the build material 106 within a predetermined temperature range.
  • the first carriage 1 16 may be moved over the build material source 108 independently from and as the second carriage 120 is moved over the print bed 102.
  • the 3D printer 200 may also include a second build material source 206 positioned on an opposite side of the print bed 102 as the build material source 108.
  • the second build material source 206 may function in similar manners to the build material source 108.
  • the second build material source 206 may provide build material 106 that the spreader 1 10 on the first carriage 1 16 may apply onto the print bed 102 or a previously formed build material layer 1 12 as the first carriage 1 16 is moved from the second build material source 206 in the direction of the first build material source 108.
  • a build material layer 1 12 may be formed as the first carriage 1 16 is moved in either or both directions across the print bed 102.
  • excess build material 106 from the formation of the build material layer 1 12 may be collected in either of the build material source 108 and the second build material source 206, for instance, to either be recycled or discarded.
  • the build material sources 108 and 206 may include bins that are to collect the excess build material 106.
  • the build material source 108 and the second build material source 206 are depicted as being positioned below the first carriage 1 16, it should be understood that the build material source 108 and/or the second build material source 206 may alternatively be positioned above the first carriage 1 16 without departing from a scope of the 3D printer 200.
  • the build material 106 may be gravity-fed onto the print bed 102.
  • the energy sources 202 and 204 may also be moved over the second build material source 206 to apply energy onto the build material 106 contained in the second build material source 206. Energy may be applied onto the build material 106 contained in the second build material source 206 to maintain the build material 106 within a predetermined temperature range.
  • the build material source 108 and the second material source 206 may be heated through other mechanisms, such as heaters positioned in or around the build material source 108 and the second material source 206.
  • the 3D printer 200 may include a temperature sensor 208 and an overhead energy source 210.
  • the temperature sensor 208 may be positioned over the print bed 102 to detect temperatures of a build material layer 1 12 formed over the print bed 102.
  • the temperature sensor 208 is to communicate the detected temperatures to the controller 130, and the controller 130 may control at least one of a wavelength and an intensity of light emitted from either or both of the energy sources 202, 204 based upon the detected temperatures.
  • the controller 130 may also control the timing at which the energy applied, e.g., pauses between application of the energy.
  • the controller 130 may further control the speed at which the first carriage 1 16 is moved across the build material layer 1 12 based upon the detected temperatures.
  • the controller 130 may control the overhead energy source 210 to vary at least one of a wavelength and an intensity of light emitted from the overhead energy source 210 onto the build material layer 1 12. In either of these examples, the amount of energy applied onto the build material layer 1 12 may be controlled to maintain the build material 106 contained in the build material layer 1 12 within a predetermined temperature range.
  • the overhead energy source 210 may be statically positioned over the print bed 102. In another example, the overhead energy source 210 may be movable, for instance, as indicated by the arrow 21 1 .
  • the overhead energy source 210 may be positioned on another carriage (not shown) that is movable along a second rail (not shown), in which the second rail is positioned in a vertically spaced relation to the rail 1 18.
  • the overhead energy source 210 may move independently from the other carriages 1 16, 120, 220 to thus apply energy as needed or desired on various locations at which the build material 106 may be provided.
  • the overhead energy source 210 may move in a parallel axis to the movement of the first carriage 1 16 and in another example, the overhead energy source 210 may move in a different axis from the movement of the first carriage 1 16, for instance, in a perpendicular axis.
  • the 3D printer 200 may also include a drive system (not shown) that the controller 130 may control to vary the position of the overhead energy source 210.
  • the 3D printer 200 may include a third carriage 220 on which is mounted a printhead (PH) 222.
  • the printhead 222 may include a plurality of nozzles (not shown) through which a fluid, such as ink, water, or the like, is to be ejected.
  • the printhead 222 may be, for instance, a thermal inkjet printhead, a piezoelectric printhead, etc.
  • the third carriage 220 may be positioned on an opposite side of the first carriage 1 16 with respect to the second carriage 120.
  • the third carriage 220 may be moved across the print bed 102 in the horizontal direction as represented by the arrow 224 to enable the printhead 222 to deposit fluid onto desired locations of the build material layer 1 12 through the nozzles.
  • the third carriage 120 has been depicted in FIG. 1 as including a single printhead 222, it should be understood that the third carriage 220 may support any reasonably suitable number of printheads in an array, in which the printheads are to deposit either one type of fluid or multiple types of fluids.
  • the controller 130 may control the printhead 222 to deposit the fluid at the locations on the build material layer 1 12 that are to be fused together or otherwise solidified in manners similar to those described above with respect to the printhead 122.
  • the controller 130 may control the printhead 222 to deposit the fluid at the desired, e.g., predetermined, locations of the build material layer 1 12 as the third carriage 220 is positioned over the build material layer 1 12.
  • the third carriage 220 may be independently movable with respect to the first carriage 1 16 and the second carriage 120 and may be movable in-line, e.g., along the same axis, as the first carriage 1 16 and the second carriage 120.
  • each of the first carriage 1 16, the second carriage 120, and the third carriage 220 may be moved to different positions and/or at different speeds independently with respect to each other.
  • the third carriage 220 may be moved synchronously or asynchronously with either or both of the first carriage 1 16 and the second carriage 120.
  • the controller 130 may control a third drive system 226 independently from the first drive system 140 and the second drive system 142 to independently control the movement and/or the speeds of movement of the third carriage 220 from the first carriage 1 16 and the second carriage 120.
  • the third drive system 226 may include a third belt and pulley system attached to the third carriage 220, in which the belt is attached to a third motor, which the controller 130 may control.
  • the independent drive systems 140, 142, and 226 enable each of the first carriage 1 16, the second carriage 120, and the third carriage 220 to be independently movable with respect to each other.
  • the third drive system 226 may include a drive system other than a belt and pulley system without departing from a scope of the present disclosure.
  • the controller 130 may control the build material source 108 to provide build material 106 between the spreader 1 10 and the print bed 102 and may control the first carriage 1 16 to move across the print bed 102 to spread the build material 106 and form a build material layer 1 12. Either following movement of the first carriage 1 16 to a position over the second build material source 206 or while the first carriage 1 16 is being moved across the print bed 102, the controller 130 may control the third drive system 226 to move the third carriage 220 and thus the printhead 222 over the formed build material layer 1 12 and to deposit fluid at desired locations of the build material layer 1 12.
  • the controller 130 may control the third drive system 226 to move the third carriage 220 in the opposite direction and may cause the first carriage 1 16 to also move in that direction over the build material layer 1 12.
  • the controller 130 may control either or both of the energy sources 202 and 204 to apply energy onto the build material layer 1 12 and the fluid to cause the sections of the build material layer 1 12 upon which the fluid was applied to fuse together as the first carriage 1 16 is moved over the build material layer 1 12.
  • an actuator may vary a vertical position of the spreader 1 10, in which movement the spreader 1 10 is represented by the arrow 228.
  • the controller 130 may control the actuator to vary the vertical position of the spreader 1 10 to be in either of a lower position and an upper position and any position between the lower position and the upper position. While in the lower position, the spreader 1 10 may contact a pile of build material 106 to spread the build material 106 over the print bed 102 and form the build material layer(s) 1 12.
  • the spreader 1 10 While in the upper position or other position above higher than the lower position, the spreader 1 10 may be spaced at a distance from the uppermost build material layer 1 12, for instance, to controllably prevent contact between the spreader 1 10 and the build material layer 1 12 during movement of the first carriage 1 16 over the build material layer 1 12.
  • the controller 130 may move the first carriage 1 16 back toward the second carriage 120 to apply additional energy onto the build material layer 1 12 until the first carriage 1 16 is positioned over the second build material source 206.
  • the controller 130 may cause the print bed 102 to be lowered, control the second build material source 206 to provide build material 106 between the spreader 1 10 and the print bed 102, and control the first carriage 1 16 to move across the print bed 102 in the direction of the third carriage 220 to spread the build material 106 and form a build material layer 1 12.
  • the controller 130 may control the third drive system 226 to move the third carriage 220 and thus the printhead 222 over the formed build material layer 1 12 and to deposit fluid at desired locations of the build material layer 1 12.
  • the controller 130 may control the third drive system 226 to move the third carriage 220 in the opposite direction and may cause the first carriage 1 16 to also move in that direction over the build material layer 1 12.
  • controller 130 may control either or both of the energy sources 202 and 204 to apply energy onto the build material layer 1 12 and the fluid to cause the sections of the build material layer 1 12 upon which the fluid was applied to fuse together as the first carriage 1 16 is moved over the build material layer 112.
  • the controller 130 may further control the first drive system 140 to move the first carriage 1 16 toward the second carriage 120. While the first carriage 1 16 moves toward the first carriage 120, either or both of the energy sources 202 and 204 may apply energy onto the build material layer 1 12. This may be done while the spreader 1 10 is in the upper position to prevent the spreader 1 10 from contacting the build material layer 1 12 as the spread 1 10 is moved across the build material layer 1 12.
  • the controller 130 may further control either or both of the energy sources 202 and 204 to apply energy onto the build material layer 1 12 during multiple passes of the first carriage 1 16 over the same build material layer 1 12.
  • the controller 130 may also control the first drive system 140 to position the first carriage 1 16 over the second build material source 206.
  • the controller 130 may cause the print bed 102 to be lowered, control the second build material source 206 to provide build material 106 between the spreader 1 10 and the print bed 102, and control the first carriage 1 16 to move across the print bed 102 toward the third carriage 220 to spread the build material 106 and form a next build material layer 1 12.
  • the controller 130 may control the second drive system 142 to move the second carriage 120 over the next build material layer 1 12 and to deposit fluid at desired locations of the next build material layer 1 12.
  • the controller 130 may control the second drive system 142 to move the second carriage 120 in the opposite direction and may cause the first carriage 1 16 to also move in that direction over the next build material layer 1 12.
  • the controller 130 may control either or both of the energy sources 202 and 204 to apply energy onto the next build material layer 1 12 and the fluid to cause the sections of the next build material layer 1 12 upon which the fluid was applied to fuse together as the first carriage 1 16 is moved over the next build material layer 1 12.
  • the first carriage 1 16 may again be moved back over the next build material layer 1 12 toward the third carriage 220 until the first carriage 1 16 is positioned over the build material source 108.
  • the controller 130 may control the build material source 108 to provide build material 106 to be spread into a next build material layer 1 12 on top of the previously formed build material layer 1 12 and the process described above may be repeated.
  • an energy source 230 may be provided on the second carriage 120 and an energy source 232 may be provided on the third carriage 220.
  • the energy sources 230 and 232 may be additional to the energy sources 202 and 204 provided on the first carriage 1 16 or may replace those energy sources 202 and 204.
  • the energy sources 230 and 232 may apply energy onto the build material layer 1 12 while the second carriage 120 and the third carriage 220 are respectively moved over a build material layer 1 12.
  • the spreader 1 10 may form a new build material layer 1 12 each time the first carriage 1 16 is moved across the print bed 102 and fluid may be applied during alternative passes by the printheads 122, 222, which may speed up the process of forming a 3D part on the print bed 102.
  • the printhead 122 may be thermally insulated from the energy source 230 and the printhead 222 may be thermally insulated from the energy source 232 to minimize damage to and/or negative effects of energy from the energy sources 230 and 232 from occurring to the printheads 122 and 222.
  • the print bed 102 is described in the examples above as being lowered prior to formation of subsequent build material layers 1 12, in other examples, the print bed 102 may remain stationary while the other components of the 3D printer 200 are moved upward between the formations of subsequent build material layers 1 12.
  • the 3D printer 200 may include service stations 240 and 242 that are to respectively service the printheads 122 and 222.
  • the service stations 240 and 242 may service the printheads 122 and 222 by performing cleaning, testing, and the like, operations on the printheads 122 and 222.
  • the controller 130 may cause the second carriage 120 to be positioned over the service station 240 according to a predefined schedule or as needed and may also control the service station 240 to perform the servicing operations on the printhead 122.
  • the controller 130 may cause the third carriage 220 to be positioned over the service station 242 according to a predefined schedule or as needed and may also control the service station 242 to perform the servicing operations on the printhead 222.
  • FIG. 3 there is shown a simplified block diagram of a 3D printer 300, according to an example. It should be understood that the 3D printer 300 depicted in FIG. 3 may include additional components and that some of the components described herein may be removed and/or modified without departing from a scope of the 3D printer 300 disclosed herein.
  • the 3D printer 300 depicted in FIG. 3 includes many of the same elements as those included in the 3D printer 200 depicted in FIG. 2. As such, the features in the 3D printer 300 that are common to the features in the 3D printer 200 will not be described in detail other than to provide a description of how those features operate in the context of the 3D printer 200. Instead, the descriptions of the common features provided above with respect to the 3D printer 200 are intended to also describe the common features contained in the 3D printer 300.
  • the 3D printer 300 is also depicted as including a management apparatus 302, a print bed actuator 304, a spreader actuator 306, and a machine-readable storage medium 310.
  • the controller 130, the data store 132, and the machine-readable storage medium 310 are depicted as being part of the management apparatus 302.
  • the management apparatus 302 may be a command module or other control system of the 3D printer 300.
  • the controller 130 may be any of a central processing unit (CPU), a semiconductor-based microprocessor, an application specific integrated circuit (ASIC), and/or other hardware device suitable for controlling operations of the 3D printer 300.
  • the controller 130 may fetch, decode, and execute instructions, such as instructions 312-326 stored on the machine-readable storage medium 310, to control processes to access a 3D part to be printed 312, control the build material source(s) 314, control the drive systems 316, control the printhead(s) 318, control the energy source(s) 320, control a print bed actuator 322, control a spreader actuator 324, and control the service station(s) 326.
  • the controller 130 may include one or more electronic circuits that include electronic components for performing the functionalities of the instructions 312-326.
  • the machine-readable storage medium 310 may be any electronic, magnetic, optical, or other physical storage device that contains or stores executable instructions.
  • the machine-readable storage medium 310 may be, for example, Random Access Memory (RAM), an Electrically Erasable Programmable Read-Only Memory (EEPROM), a storage device, an optical disc, and the like.
  • the machine-readable storage medium 310 may be a non-transitory machine-readable storage medium, where the term "non-transitory" does not encompass transitory propagating signals.
  • machine-readable storage medium 310 may be encoded with a series of executable instructions 312-326 to control operations of the 3D printer 300.
  • controller 130 may instead communicate, e.g., send instructions to the various components of the 3D printer 300 via an interface (not shown).
  • the interface may include hardware and/or software to enable the controller 130 to communicate with the various components.
  • FIGS. 4 and 5 depict flow diagrams of methods 400 and 500 for operating a 3D printer 100, 200, 300 to form a 3D object, according to an example. It should be apparent to those of ordinary skill in the art that the methods 400 and 500 may represent generalized illustrations and that other operations may be added or existing operations may be removed, modified, or rearranged without departing from the scopes of the methods 400 and 500. Generally speaking, the controller 130 depicted in FIGS. 1 -3 may implement either or both of the methods 400 and 500.
  • the controller 130 may execute the instructions 312 to access data of a 3D object to be printed.
  • the data of the 3D object to be printed may include information pertaining to the locations on each of the respective build material layers 1 12 at which fluid is to be deposited during a printing operation.
  • the controller 130 may execute the instructions 314 to cause the build material source 108 to provide build material 106 between the spreader 1 10 and the print bed 102.
  • the controller 130 may execute the instructions 316 to control the first drive system 140 to cause the first carriage 1 16 to move in a direction across the print bed 102 such that the spreader 1 10 spreads the build material 106 over the print bed 102 to form a build material layer 1 12 over the print bed 102.
  • the controller 130 may execute the instructions 312 to control the second drive system 142 to cause the second carriage 120 to move across the print bed 102.
  • the controller 130 may execute the instructions 312 to independently control the second drive system 142 with respect to the first drive system 140, such that the second carriage 120 moves independently from the first carriage 1 16.
  • the controller 130 may execute the instructions 318 to control the printhead 122 to deposit a fluid at predetermined locations on the build material layer 1 12 while the second carriage 120 is positioned over the build material layer 1 12. The predetermined locations at which the fluid is deposited may be identified in the data accessed at block 402.
  • the controller 130 may execute the instructions 312 to determine whether an additional build material layer 1 12 is to be formed as part of the printing of the 3D object. In response to a determination that an additional build material layer 1 12 is to be formed, the controller 130 may execute the instructions 322 to control the print bed actuator 304 to vary the position of the print bed 102 such that the print bed 102 is moved in a downward direction, as indicated at block 414. In addition, at block 416, the controller 130 may execute the instructions 314 to provide additional build material 106 between the spreader 1 10 and the print bed 102. Moreover, the controller 130 may repeat blocks 406-416 to form additional build material layers 1 12 of the 3D object until the controller 130 determines that no additional layers are to be added at block 412, at which point the method 400 may end as indicated at block 418.
  • the controller 130 may execute the instructions to implement blocks 402-410 as described above with respect to the method 400 depicted in FIG. 4.
  • the method 500 may thus include additional features as compared with the method 400.
  • the controller 130 may execute the instructions 320 to cause energy to be applied to the build material layer 1 12 and the deposited fluid.
  • the energy may be applied to the build material layer 1 12 and the deposited fluid through any of a plurality of energy sources 202, 204, 230, and 232, which may be provided on any of the first carriage 1 16, the second carriage 120, and the third carriage 220.
  • the energy may be applied to the build material layer 1 12 and the deposited fluid as one or more of the first carriage 1 16, the second carriage 120, and the third carriage 220 are moved across the build material layer 1 12.
  • application of the energy may cause the build material 106 upon which the fluid has been deposited to fuse together.
  • the overhead energy source 210 may apply energy to the build material layer 1 12 and the deposited fluid as further described above.
  • the controller 130 may execute the instructions 312 to determine whether an additional build material layer 1 12 is to be formed as part of the printing of the 3D object. In response to a determination that an additional build material layer 1 12 is to be formed, the controller 130 may execute the instructions 322 to control the position of the print bed 102 such that the print bed 102 is moved in a downward direction, as indicated at block 508. In addition, at block 510, the controller 130 may execute the instructions 314 to provide additional build material 106 between the spreader 1 10 and the print bed 102.
  • the first carriage 1 16 may have been moved back over a first build material source 108 and the additional build material 106 may be provided from the first build material source 108.
  • the controller 130 may execute the instructions 316 to cause the first carriage 1 16 to be moved in a direction toward the second carriage 120 to cause the spreader 1 10 to spread the build material 106 and form a next build material layer 1 12 on top of the previously formed build material layer 1 12.
  • the controller 130 may cause the first carriage 1 16 to be moved in an opposite direction away from the second carriage 120, for instance, with the spreader 1 10 in a raised position.
  • the controller 130 may execute the instructions 316 to cause the second carriage 120 to move over the next build material layer formed over the print bed 102 independently of the first carriage 1 16. Moreover, at block 516, the controller 130 may execute the instructions 318 to cause the printhead 122 to deposit fluid while the second carriage 120 is over the next build material layer. Still further, at block 518, the controller 130 may execute the instructions 320 to control application of energy on the next build material layer in any of the manners described above. Following block 518, the controller 130 may execute the instructions 312 to determine whether an additional build material layer 1 12 is to be formed as part of the printing of the 3D object, as indicated at block 506.
  • the controller 130 may repeat blocks 506-518 to form the additional build material layers 1 12 of the 3D object until the controller 130 determines that no additional layers are to be added at block 506, at which point the method 500 may end as indicated at block 520.
  • the first carriage 1 16 may be positioned over the first build material source 108 and the additional build material 106 may be provided from the first build material source 108.
  • the controller 130 may execute the instructions 316 to cause the first carriage 1 16 to be moved in a direction toward the second carriage 120 to cause the spreader 1 10 to spread the build material 106 and form a next build material layer on top of a previously formed build material layer 1 12.
  • the controller 130 may execute the instructions 316 to cause the third carriage 220 to be moved in the direction toward the second carriage 120 over the next build material layer.
  • the controller 130 may control movement of the third carriage 220 independently from the movement of the first carriage 1 16.
  • the controller 130 may execute the instructions 318 to cause the printhead 222 to deposit fluid while the third carriage 220 is positioned over the next build material layer.
  • the controller 130 may execute the instructions 320 to control application of energy on the next build material layer in any of the manners described above. That is, for instance, an energy source 232 may be provided on the third carriage 220 and the energy source 232 may apply energy onto the next build material layer as the third carriage 220 is moved toward the second carriage 120, following deposition of the fluid by the printhead 222. In addition, or alternatively, the energy source 232 may apply energy onto the next build material layer as the third carriage 220 is moved away from the second carriage 120. The printhead 222 may or may not deposit fluid during this movement.
  • the controller 130 may execute the instructions 312 to determine whether an additional build material layer 1 12 is to be formed as part of the printing of the 3D object, as indicated at block 506.
  • the controller 130 may implement a second iteration of the second example. Particularly, the controller 130 may move the print bed 102 as indicated at block 508 and may execute the instructions 314 to provide additional build material 106 from the second build material source 208 between the spreader 1 10 and the print bed 102.
  • the first carriage 1 16 may be positioned over the second build material source 206 and the third carriage 220 may be moving away from the first carriage 1 16 or may have reached a resting position, e.g., above the service station 242.
  • the controller 130 may execute the instructions 316 to cause the first carriage 1 16 to be moved in a direction toward the third carriage 220 to cause the spreader 1 10 to spread the build material 106 and form a next build material layer on top of a previously formed build material layer.
  • the controller 130 may execute the instructions 316 to cause the second carriage 120 to be moved in the direction toward the third carriage 220 over the next build material layer.
  • the controller 130 may execute the instructions 318 to cause the printhead 122 to deposit fluid while the second carriage 120 is over the next build material layer.
  • the controller 130 may execute the instructions 320 to control application of energy on the next build material layer in any of the manners described above. That is, for instance, an energy source 230 may be provided on the second carriage 120 and the energy source 230 may apply energy onto the next build material layer as the second carriage 120 is moved toward the third carriage 220, following deposition of the fluid by the printhead 122. In addition, or alternatively, the energy source 230 may apply energy onto the next build material layer as the second carriage 120 is moved away from the third carriage 120. The printhead 122 may or may not deposit fluid during this movement.
  • the controller 130 may execute the instructions 312 to determine whether an additional build material layer 1 12 is to be formed as part of the printing of the 3D object, as indicated at block 506.
  • a third iteration of the second example may be implemented, in which the first carriage 1 16 is moved toward the second carriage 120 and the printhead 222 on the third carriage 220 applies a fluid onto the next build material layer. If additional layers are to be formed, the second carriage 120 and the third carriage 220 may alternatively be moved across the next build material layer during each iteration of the second example.
  • the additional layers may be formed and predetermined sections of the additional layers may be fused together during each build material layer formation pass of the first carriage 1 16 instead of having to wait for the first carriage 1 16 to be returned to a starting location, i.e., requiring the first carriage 1 16 to perform multiple passes during each fluid deposition process.
  • controller 130 may repeat blocks 506-518 to form the additional build material layers 1 12 of the 3D object until the controller 130 determines that no additional layers are to be added at block 506, at which point the method 500 may end as indicated at block 520.
  • Some or all of the operations set forth in the methods 400 and 500 may be contained as utilities, programs, or subprograms, in any desired computer accessible medium.
  • the methods 400 and 500 may be embodied by computer programs, which may exist in a variety of forms both active and inactive. For example, they may exist as machine readable instructions, including source code, object code, executable code or other formats. Any of the above may be embodied on a non-transitory computer readable storage medium.
  • Examples of non-transitory computer readable storage media include computer system RAM, ROM, EPROM, EEPROM, and magnetic or optical disks or tapes. It is therefore to be understood that any electronic device capable of executing the above-described functions may perform those functions enumerated above.
  • FIG. 6 there is shown a schematic representation of a management apparatus 600, which may be equivalent to the management apparatus 302 depicted in FIG. 3, according to an example.
  • the management apparatus 600 may include a processor 602, a display 604; an interface 608; and a computer-readable medium 610. Each of these components may be operatively coupled to a bus 612.
  • the bus 612 may be an EISA, a PCI, a USB, a FireWire, a NuBus, or a PDS.
  • the computer readable medium 610 may be any suitable medium that participates in providing instructions to the processor 602 for execution.
  • the computer readable medium 610 may be non-volatile media, such as an optical or a magnetic disk; volatile media, such as memory.
  • the computer-readable medium 610 may also store 3D printer control machine readable instructions 614, which, when executed may cause the processor 602 to perform either or both of the methods 400 and 500 depicted in FIGS. 4 and 5.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

L'invention concerne une imprimante tridimensionnelle (3D) pouvant comprendre un lit d'impression, un premier chariot à déplacer sur le lit d'impression, un dispositif d'étalement monté sur le premier chariot permettant d'étaler un matériau de fabrication sur le lit d'impression, le matériau de fabrication devant être formé, couche-par-couche, en un objet tridimensionnel (3D), un second chariot à déplacer sur le lit d'impression de sorte que le premier chariot et le second chariot sont indépendamment mobiles sur le lit d'impression linéairement l'un par rapport à l'autre, une tête d'impression positionnée sur le second chariot, la tête d'impression étant destinée à déposer un fluide sur le matériau de fabrication étalé de manière commandée, et un dispositif de commande permettant de commander indépendamment le mouvement du premier chariot et du second chariot sur du lit d'impression.
PCT/US2015/043289 2015-07-31 2015-07-31 Imprimante 3d à multiples chariots WO2017023281A1 (fr)

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WO2018194668A1 (fr) * 2017-04-21 2018-10-25 Hewlett-Packard Development Company, L.P. Synchronisation de chariots
US11628626B2 (en) 2017-04-21 2023-04-18 Hewlett-Packard Development Company, L.P. Recoater movement
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CN109016494B (zh) * 2018-10-17 2024-04-02 云南三帝科技有限公司 悬挂式3d打印机传动机构
US11660809B2 (en) 2018-12-07 2023-05-30 Stratasys Powder Production Ltd. Sled configurations and methods of operation for the manufacture of three-dimensional objects
WO2020237166A3 (fr) * 2019-05-23 2021-02-25 General Electric Company Ensembles actionneurs d'appareils de fabrication additive et leurs procédés d'utilisation
CN113825623A (zh) * 2019-10-02 2021-12-21 惠普发展公司，有限责任合伙企业 承载相应能量源的独立可移动滑架
EP3941720A4 (fr) * 2019-10-02 2022-10-26 Hewlett-Packard Development Company, L.P. Chariots mobiles indépendamment portant des sources d'énergie respectives
WO2022086503A1 (fr) * 2020-10-20 2022-04-28 Hewlett-Packard Development Company, L.P. Impression à chariots multiples
US12005642B2 (en) 2021-06-04 2024-06-11 Stratasys Powder Production Ltd. Sled configurations and methods of operation for the manufacture of three-dimensional objects
WO2023069090A1 (fr) * 2021-10-20 2023-04-27 Hewlett-Packard Development Company, L.P. Imprimantes 3d

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