WO2020159485A1 - Éléments compressibles - Google Patents

Éléments compressibles Download PDF

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Publication number
WO2020159485A1
WO2020159485A1 PCT/US2019/015731 US2019015731W WO2020159485A1 WO 2020159485 A1 WO2020159485 A1 WO 2020159485A1 US 2019015731 W US2019015731 W US 2019015731W WO 2020159485 A1 WO2020159485 A1 WO 2020159485A1
Authority
WO
WIPO (PCT)
Prior art keywords
build
compressible element
cover plate
object generation
generation volume
Prior art date
Application number
PCT/US2019/015731
Other languages
English (en)
Inventor
Mohammad JOWKAR
Rhys MANSELL
Adrien CHIRON
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/US2019/015731 priority Critical patent/WO2020159485A1/fr
Publication of WO2020159485A1 publication Critical patent/WO2020159485A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255—Enclosures for the building material, e.g. powder containers
    • 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
    • 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
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • Some additive manufacturing or three-dimensional printing systems selectively solidify portions of successive layers of a powdered build material.
  • selective solidification may be achieved by selectively applying an energy absorbing fusing agent over each formed layer of build material and applying a fusing energy to the build material layer to cause portions thereof on which fusing agent was printed to heat up sufficiently to melt, coalesce, sinter, or otherwise fuse, and then to solidify upon cooling.
  • Other examples directly apply energy in a point-to-point manner to portions of each layers to be solidified, for example using a laser.
  • Fig. 1A is a schematic diagram showing an example of a build unit.
  • Fig. IB is a schematic diagram showing a top view of an example of a build unit.
  • Fig. 2A is a schematic diagram showing an example of a build unit.
  • Fig. 2B is a schematic diagram showing a top view of an example of a build unit.
  • Fig. 3A is a schematic diagram showing an example of a compressible element.
  • Fig. 3B is a schematic diagram showing an example of a plurality of stacked compressible elements.
  • Fig. 4A is a schematic diagram showing an example of a build unit.
  • Fig. 4B is a schematic diagram showing a representation of a cross-section of an example of a build unit.
  • Fig. 4C is a schematic diagram showing a representation of a cross-section of an example of a build unit.
  • Fig. 5 is a schematic diagram showing an example of a build unit.
  • Fig. 6 is a schematic diagram showing an example of a three-dimensional printer.
  • Fig. 7 is a flow diagram illustrating an example method to generate an object.
  • Fig. 8 is a flow diagram illustrating another example method to generate an object.
  • Powder-based build materials for use in examples herein may include, where appropriate, suitable plastic build material such as PA12, PA11, TPU, or any other plastic build material. In other examples, the build material may be any suitable metal or ceramic build material.
  • to fuse shall be understood as comprising, where appropriate, at least one of: to fuse, to melt, to solidify, to coalesce, to cure, and to sinter.
  • fuse fuse
  • melting module solidifying module
  • coalescing module coalescing module
  • curing module cusintering module
  • Fig. 1A and IB shows an example of a build unit 100.
  • Fig. 1A illustrates a front view of a cross section of the middle of the build unit 100.
  • Fig. IB illustrates an example of top view of the build unit 100.
  • the build unit 100 comprises rigid build unit walls 110 and a build unit base 120 and forms a generally open-topped cuboidal build chamber 150.
  • the build unit base 120 is a fix platform substantially parallel to the ground level.
  • the build unit 100 comprises moveable means, e.g. wheels, to transport the build unit 100 from one place to another within a working environment.
  • the build unit 100 may be removed from a 3D printing system after the generation of the object.
  • the build unit 100 without wheels is integrated into the 3D printing system 100.
  • the build chamber 150 comprises therein an object generation volume, defines the volume in which three-dimensional objects may be generated. A reduction of the build chamber 150 leads to a reduction of the object generation volume.
  • the build chamber 150 comprises a build platform 130 therein.
  • the build platform 130 is moveable within the build chamber 150.
  • the build platform 130 is movable substantially vertically within the build chamber, when the build unit is in a normal upright orientation.
  • the build platform 130 may be placed in an upper position at the beginning of the printing operation and may be lowered a vertical distance corresponding to the thickness of each layer to be formed.
  • the thickness of the subsequent layer may be in the range of about the 40 microns to 120 microns, for example 80 microns.
  • the build chamber 150 has a uniform cross-section with regard to the vertical axis 152.
  • Different 3D printer users may have different needs at different times. For example, during an object prototyping phase, users may place a higher priority on speed when generating a single or low number of objects. In such a case it may be inefficient to use the full volume of the build chamber 150 to generate objects that will occupy a small portion of the build chamber 150.
  • powdered build material may be exposed to heat and humidity during the object generation phase which may lead to a degradation of the powder. This degradation may affect the ability of the powdered build material to be recycled for use in future print jobs.
  • Fig. 2A and 2B show an example of a build unit 100.
  • Fig. 2A illustrates a front view of a cross section of the middle of the build unit 100.
  • Fig. 2B illustrates an example of top view of the build unit 100.
  • the build unit 100 may be fitted with a cover plate 240B-D.
  • a cover plate 240B-D To more clearly differentiate the build unit 100 elements and the cover plate 240, diagonal linear hatching has been used to indicate the build unit 100 elements, and vertical linear hatching has been used to indicate the cover plate 240.
  • the cover plate 240 is designed to be removably insertable into, or attachable to, the build unit 100 to enable, along with a compressible element placed between the cover plate 240 and the build platform 130, the effective size of the build chamber 100 to be reduced.
  • the build unit 100 is to fixably receive the cover plate 240 to reduce the cross section of an opening of the build chamber 150.
  • the build unit 100 may comprise receiving means to receive the cover plate 240, such as, grooves, fixation points, sensors, etc.
  • the cover plate 240 may be fixably inserted within the build unit walls 110. The size of the cover plate 240 determines the section of the object generation volume, thereby enabling, when fitted, the 3D printer to print objects in a reduced size build volume compared to the full volume of the build chamber 150.
  • the cover plate 240 may be formed of any suitable rigid material, including metal. In some examples, the cover plate 240 may be additionally formed from a high-temperature resistant material. [0027] In the illustrated example, the cover plate 240 may comprise a plurality of individual cover plate modules 240A-D to be assembled together. In another example, the cover plate 240 may be an integral cover plate 240 to be fitted to the build unit 100. For simplicity and illustrative purposes, the examples hereinafter make reference to the integral cover plate 240. [0028] Fig. BA illustrates an example of a compressible element 360 according to an example. The compressible element 360 is to be placed between the cover plate 240 and the build platform 130.
  • the compressible element 360 is a cuboid that has a cross-section that substantially corresponds to the cross-section of the cover plate 240.
  • the compressible element 360 is formed from a plurality of individual compressible elements which are to be placed between the cover plate 240 and the build platform 130 so that the overall cross-section of the plurality of individual compressible elements combined, corresponds to the cross-section of the cover plate 240.
  • the compressible element 360 is intended to occupy the volume comprised vertically between the cover plate 240 and the build platform 130.
  • the height of the compressible element 360 in its uncompressed state may be based on the height of the desired build job to be printed.
  • the build job may comprise the object or plurality of objects to be printed in the print job.
  • the height of a compressible element 360 of a build job having a height of 10cm may be selected as having at least a height of 10cm.
  • the height of the compressible element 360 in its uncompressed state may be selected to further include an additional, height corresponding to the height of the fully elastically compressed compressible element 360.
  • the compressible element 360 may be formed from any suitable compressible material.
  • a compressible element may be formed from a material formed by trapping pockets of gas in a liquid or solid, such as a foam-type element.
  • Some examples of elastically compressible element 360 have a height, in a fully compressed state, that is in the region of about ten times smaller than the height of the compressible element 360 when in an uncompressed state. Such elements may be known as 'hyper- compressible' elements.
  • Some examples of elastically compressible element 360 have a height, in a fully compressed state, that is five times smaller than the height of the compressible element 360 when in an uncompressed state.
  • Some examples of elastically compressible element 360 have a height, in a fully compressed state, that is two times smaller than the height of the compressible element 360 when in an uncompressed state.
  • the compressibility of a compressible element 360 may be measured through the compression force deflection parameter.
  • the compression force deflection may be measured by a universal tensile testing machine with a flat compression foot.
  • other similar parameters comprising a conversion from the compression force deflection parameter may be used without departing from the scope of the present disclosure.
  • the compressible element 360 has a compression force deflection from about 2kPa to about 15kPa. In other examples, the compressible element 360 has a compression force deflection from about 5kPa to about lOkPa. In other examples, the compressible element 360 has a compression force deflection from about 7.5kPa to about 12kPa. In other examples, the compressible element 360 has a compression force deflection from about 9kPa to about 14kPa.
  • Fig. 3B illustrates an example of a plurality of individual vertically stacked compressible elements 360A-F according to an example (see, e.g. vertical axis 152).
  • the plurality of vertically stacked compressible elements 360A-F may be used for the same purposes and in the same way as the compressible element 360 from Fig. 3A.
  • the total height of the stacked compressible elements 360A-F may be the same as or similar to the height of the compressible element 360 from Fig. 3A.
  • each of the stacked compressible elements 360A-F has the same height.
  • different stacked compressible elements 360A-F have different heights.
  • each of the stacked compressible elements 360A-F is a cuboid having substantially the same cross-section as the compressible element 360 but having each individual compressible element 360A-F a different height than the compressible element 360 from Fig. 3A.
  • each of the stacked compressible elements 360A-F has a non-uniform geometry other than a cuboid, for example, a triangular prism shape.
  • a stacked compressible element 360A-F having a non-uniform geometry has a lower overall mass density as opposed to the corresponding compressible element 360A-F having a cuboid geometry, since a portion of the volume between two stackable compressible elements may comprise air rather than the compressible element material.
  • a lower mass density enables the compressible element to be more elastically compressed as opposed to a compressible element with a higher mass density.
  • the compressible elements may have a different horizontal cross-section than the cover plate 240 (see, e.g. horizontal axis 154).
  • a plurality of compressible elements may be arranged horizontally so that the total length and width corresponds to the cross-section of the cover plate 240.
  • the plurality of compressible elements may be stacked vertically and horizontally so that the total length and width corresponds to the cross-section of the cover plate 240 and the total height corresponds to the height as defined in the compressible element 360 from Fig. 3A.
  • Fig. 4A and 4B illustrate an example of a build unit 100. Fig.
  • FIG. 4A illustrates a front view of a cross-section of the middle of the build unit 100 of the example and Fig. 4B illustrates an example of top view of the example corresponding to the cross-section A-A' from Fig. 4A.
  • the example of Fig. 4A and 4B illustrates the configuration of the build unit 100 after the set-up of the build unit 100 for the print job but before starting the printing operation to generate an object.
  • the cover plate 240 has been attached to the top of the build chamber 150 to reduce the cross-section of the opening of the build chamber 150.
  • the build unit 100 has also received a compressible element 360 placed between the cover plate 240 and the build platform 130 to reduce the object generation volume.
  • a diagonal linear hatching has been used to indicate the build unit 100 elements
  • a vertical linear hatching has been used to indicate the cover plate 240
  • a cross-hatching has been used to indicate the compressible element 360.
  • cover plate 240 and/or the compressible element 360 may be introduced to the build unit 100 manually by the user or automatically by a suitable robot controlled by a remote controlling entity (not shown).
  • the object generation volume is reduced in size.
  • a reduced object generation volume may enable a faster generation of the objects therein.
  • a reduced object generation volume results in a reduced amount of build material being used.
  • a reduced object generation volume may result in less build material being exposed to potentially damaging heat or solvents compared to using the full build chamber 150.
  • the cover plate 240, and the compressible element 360 may be provided as a kit of parts.
  • a kit of parts should be interpreted as physically independent individual elements that have a shared interaction functionality, for example as an accessory to be used in a build unit 100 but without being mounted in the build unit yet.
  • Fig. 4C illustrates an example of a build unit 100.
  • the illustration of build unit 100 may correspond to the build unit 100 of Fig. 4A and 4B once the build platform 130 has been moved to its highest position.
  • Some 3D printing systems start the printing operation by moving the build platform 130 to the highest position within the build unit 100.
  • Raising the build platform 150 causes the compressible element 360 to be compressed as soon as it reaches the cover plate 240. The more the build platform 150 moves vertically towards the cover plate 240, the more the compressible element 360 is compressed.
  • the compressible element 360 has been selected so that when the build platform 130 reaches its highest position, the compressible element 360 does not deform plastically. Therefore, once the compressible element 360 is removed from the build unit 100, it may return to its original shape without experiencing any permanent deformation and can be used in future print jobs.
  • the compressible element 360 is deformed plastically once the build platform 130 reached its highest position. In an example, the compressible element 360 is reused for further print jobs regardless of a potential permanent deformation. In another example, the compressible element 360 is not re-usable.
  • Fig. 5 illustrates an example of a build unit 100.
  • the compressible element is an inflatable membrane 560, such as an air bag.
  • the inflatable membrane 560 may be inflated and deflated based on the position of the build platform 130 so that the cross- section of the reduced object generation volume remains substantially constant throughout the generation of the object.
  • the inflation and deflation of the inflatable membrane 560 may be performed by a suitable blower and vacuum, controlled by an external controlling device installed, for example, in a 3D printer.
  • the inflatable membrane 560 may have the same or similar functionality as the compressible element 360.
  • Fig. 6 shows an example of a three-dimensional printer 600.
  • the three-dimensional printer 600 comprises a powder distribution module 670, a fusing module 680 and the build unit 100.
  • the build unit 100 is attachable and detachable from the three- dimensional printer 600.
  • the build unit 100 is a fixed built-in part of the three-dimensional printer 600.
  • the powder distribution module 670 is to form successive layers of build material on the reduced cross-section of the build platform 130, or on a previously formed layer.
  • the powder distribution module 670 may be a roller, a wiper, or any suitable mechanism to spread build material on the build platform 130 in the form of a build material layer.
  • the powder distribution module 670 may be mounted on a carriage (not shown) that is to move over the build platform 130 to generate a layer of build material.
  • the powder distribution module 670 may move substantially parallel over the build platform 130, for example, through a guide or track as indicated by the dashed arrow 675.
  • the build material may be supplied from a build material reservoir (not shown) using a suitable build material supply mechanism (not shown).
  • Some examples of the powder distribution module 670 encompass the full width of the full build chamber. Other examples of powder distribution module 670, however, encompass a reduced width of the full build chamber, for example a width corresponding to the reduced size build chamber 150.
  • the fusing module 680 is to selectively solidify portions of a layer of build material formed in the build chamber 150, e.g. the uppermost layer of build material on the build platform 130.
  • the term “solidify” and similar terms should be read in their respective broad definition, therefore including “partially solidify", and “totally solidify”.
  • the fusing module 680 may be fixed above the build platform 130.
  • the fusing module 680 may be moveable over the build platform 130, for example, through a carriage (not shown) scannable over the build platform 130.
  • the fusing module 680 and the powder distribution module 670 may be installed in the same carriage.
  • the fusing module 680 may be also to selectively jet a printing fluid, such as an energy absorbing fusing agent, or a binder agent, on a build material layer.
  • the selection of the suitable fusing module 680 may be based on the build material to be used.
  • the fusing module 680 may comprise an array of ultraviolet (UV) Light Emitting Diodes (LED) that emit electromagnetic energy in about the 300nm to 410nm range.
  • the fusing module 680 may comprise at least one infrared lamp that emits electromagnetic energy in about the 700nm to 1mm range.
  • the fusing module 680 may comprise at least one lighting element that emits electromagnetic energy in about the 380nm to 750nm range.
  • the object is to be generated using on a polymeric build material.
  • the powder distribution module 670 is to form subsequent layers of the polymeric build material and the fusing module 680 is to selectively raise the temperature of the layer of polymeric build material above the melting point of the polymeric build material, so that the melted parts can solidify upon cooling.
  • the object is to be generated using a metallic build material.
  • the powder distribution module 670 is to form subsequent layers of the metallic build material and the fusing module 680 is to selectively cure the plurality of layers of the metallic build material within the object generation volume.
  • Some additive manufacturing systems comprising metallic build materials, selectively jet curable binding agents including, for example, a polymeric or chemical binder dissolved in a liquid carrier. The curing of the curable binding agents may cause the particles from the binding agent to bind together.
  • the curing operation may be performed through an ultraviolet energy source.
  • the curing operation may be performed by a thermal energy source.
  • the thermal curing may comprise the evaporation of the liquid carrier so that the layers of metallic build material in the build chamber 150 are free of the liquid carrier.
  • the fusing module 680 may cure the build material from the build chamber 150 in a layer-by-layer basis in the three-dimensional printer 600, or in an external heating entity.
  • the printed objects may be subject to an additional post-processing after the curing, for example, a sintering process in a furnace.
  • the three-dimensional printer 600 further comprises a controller 690.
  • the controller 690 may receive a print job 696 including the virtual slices corresponding to the physical object layers to generate at least one object in the reduced object generation volume.
  • the controller 690 may be any combination of hardware and programming to implement, for example, the functionalities resulting from the execution of some of the elements of method 700 of Fig. 7 or method 800 of Fig. 8. In some examples herein, such combinations of hardware and programming may be implemented in a number of different ways. For example, the programming of modules may be processor-executable instructions to perform the method 700 of Fig. 7 and/or method 800 from Fig.
  • the hardware for modules may include at least one processor 692 to execute those instructions.
  • multiple modules may be collectively implemented by a combination of hardware and programming, as described above.
  • the functionalities of the controller 130 may be, at least partially, implemented in the form of electronic circuitry.
  • Fig. 7 is a flow diagram illustrating an example method to generate an object according to an example. Parts of the method 700 may be executed or performed by a controller, such as the controller 690 of FIG. 6. Other parts of the method 700 may be performed by a user or executed by a robot. Method 700 may be implemented in the form of executable instructions stored on the machine-readable storage medium 694 and executed by a single processor 692 or a plurality of processors, and/or in the form of any electronic circuitry, for example digital and/or analog ASIC. In some implementations of the present disclosure, method 700 may include more or less elements than are shown in FIG. 7. In some implementations, some of the elements of method 700 may, at certain times, be performed in parallel and/or may repeat.
  • the controller 690 may receive a print job data 696 corresponding a set of objects to be generated.
  • the print job data 696 to print the set of objects may be derived from a SD object model of the object.
  • the SD object model may be a Computer Aid Design (CAD) file.
  • the print job data 696 may, in one example, comprise a plurality of 2D slices corresponding to virtual cross sections of the object to be generated. Each slice may correspond to a physical build material layer.
  • the 3D object model may be defined in a vector- type format from which 2D rasterized images may be generated from each slice of the set of object models.
  • the print job data 696 may also comprise instructions or data indicating which locations of the build material layer are to be solidified to generate the set of objects.
  • the controller 690 receives a set of individual object models and can determine a special arrangement within the available build volume. In other examples, however, the controller 690 receives a virtual build volume model comprising a set of pre arranged objects to be printed within the available build volume. The controller 690 may check whether the received virtual build volume model is compatible with the available build volume and whether the received virtual build volume mode is further compatible with a reduced build material volume.
  • the controller 690 may also determine if the dimensions of the set of objects from the print job data 696 can be generated in a reduced object generation volume.
  • the print job data 696 comprises an object to be generated
  • the controller 690 is to determine the reduced object generation volume to host at least the object to be generated. If the controller 690 determines that the set of objects can be generated in the reduced object generation volume, the controller 690 is further to indicate a user or a robot to install the cover IB plate 240 and compressible element 360 corresponding to the reduced object generation volume.
  • the controller 690 may also refuse the print job if the set of objects to be generated cannot fit in the reduced size build chamber 150.
  • the controller 690 is to determine the lowest usable position of the build platform 130 based on the compressibility of the type of compressible element 360 chosen. If the lowest usable position has been determined, the controller 690 is further to prevent the build platform 130 from moving vertically below the lowest usable position. If no lowest usable position has been determined, the controller 690 may acknowledge the position where the build platform 130 is in contact with the build unit base 120 as the lowest usable position. At block 740, the controller 690 may control the build platform 130 to move to the lowest usable position.
  • the user or a robot may attach the cover plate 240 to the build unit 100, and may insert the compressible element 360 between the cover plate 240 and the build platform 130 to reduce the object generation volume to the determined reduced object generation volume.
  • the controller 690 may realize that the cover plate 240 and/or the compressible element 360 are properly installed through, for example, switches, sensors, user interaction in a user interface, or any other suitable method.
  • the controller 690 may control the powder distribution module 670 to form successive layers of build material in the reduced object generation volume. Finally, at block 770, the controller 690 may control the fusing module 680 to selectively solidify portions of the formed layers to generate the set of objects associated with the print job data 696.
  • Fig. 8 is a flow diagram illustrating an example method 800 to generate an object according to an example. Parts of the method 800 may be executed or performed by a controller, such as the controller 690 of FIG. 6. Other parts of the method 800 may be performed by a user or executed by a robot. Method 800 may be implemented in the form of executable instructions stored on the machine-readable storage medium 694 and executed by a single processor 692 or a plurality of processors, and/or in the form of any electronic circuitry, for example digital and/or analog ASIC. In some implementations of the present disclosure, method 800 may include more or less elements than are shown in FIG. 8. In some implementations, some of the elements of method 800 may, at certain times, be performed in parallel and/or may repeat.
  • the controller 690 may receive a print job data 696 corresponding to a set of objects to be generated.
  • block 810 and the print job data 696 may be the same as or similar to block 710 and the print job data 696 disclosed with reference to Fig. 7.
  • the user or a robot may attach a cover plate 240 to the build unit 100 and may insert the compressible element 360 between the cover plate 240 and the build platform 130 to reduce the object generation volume to the determined reduced object generation volume.
  • block 810 may be performed before block 820. In other examples, block 820 may be performed before block 810.
  • the controller 690 may determine if the cover plate 240 and/or the compressible element 360 is present in the build chamber 150. The controller 690 may determine if the cover plate 240 and compressible element 360 are properly installed through, for example, switches, sensors, user interaction via a user interface, or any other suitable method. If the controller 690 has determined that the cover plate 240 is present in the build chamber 150, the controller 690 may execute block 840.
  • the controller 690 may determine if the set of objects can be generated in a reduced object generation volume corresponding to the cover plate 240. In an example, the controller 690 may determine if the dimensions of the set of objects from the print job data 696 can be generated in a reduced object generation volume. In an example, the print job data 696 comprises an object to be generated, the controller 690 is to determine the minimum reduced object generation volume to host at least the object to be generated. The controller 690 may also determine if the actual reduced object generation volume can host the previously determined minimum reduced object generation volume. The controller 690 may refuse the print job if the object or the set of objects to be generated cannot fit in the reduced object generation volume.
  • the controller may execute blocks 870 and 880 if the set of objects to be generated fit in the reduced object generation volume.
  • the controller 690 is to determine the lowest usable position of the build platform 130 based on the compressibility of the type of compressible element 360 chosen. If the lowest usable position has been determined, the controller 690 is further to prevent the build platform 130 from moving vertically below the lowest usable position. If no lowest usable position has been determined, the controller 690 may acknowledge the position where the build platform 130 is in contact with the build unit base 120 as the lowest usable position. At block 860, the controller 690 may control the build platform 130 to move to the lowest usable position.
  • blocks 850 and 860 may be the same as or similar to blocks 730 and 740 from Fig. 7.
  • the controller 690 may control the powder distribution module 670 to form successive layers of build material in the reduced object generation volume.
  • the controller 690 may control the fusing module 680 to selectively solidify portions of the formed layers to generate the set of objects associated with the print job data 696.
  • blocks 870 and 880 may be the same as or similar to blocks 760 and 770 from Fig. 7.
  • the above examples may be implemented by hardware, or software in combination with hardware.
  • the various methods, processes and functional modules described herein may be implemented by a physical processor (the term processor is to be implemented broadly to include CPU, SoC, processing module, ASIC, logic module, or programmable gate array, etc.).
  • the processes, methods and functional modules may all be performed by a single processor or split between several processors; reference in this disclosure or the claims to a "processor” should thus be interpreted to mean “at least one processor”.
  • the processes, method and functional modules are implemented as machine-readable instructions executable by at least one processor, hardware logic circuitry of the at least one processors, or a combination thereof.
  • the term "about” and “substantially” are used to provide flexibility to a numerical range endpoint by providing that a given value may be, for example, an additional 20% more or an additional 20% less than the endpoints of the range.
  • the degree of flexibility of this term can be dictated by the particular variable and would be within the knowledge of those skilled in the art to determine based on experience and the associated description herein.
  • a build unit comprising: a build chamber defining an open-topped object generation volume having a uniform cross-section; a build platform to move vertically within the object generation volume; the build unit comprising fixation elements to fixably receive a cover plate to reduce the cross-section of an opening of the build chamber; and
  • the build unit to receive a compressible element to be placed between the cover plate and the build platform to reduce the object generation volume.
  • Feature set 2 A build unit with feature set 1, further comprising the cover plate fixed within the build unit walls.
  • Feature set 3 A build unit with any of feature sets 1 or 2, further comprising the compressible element and wherein the compressible element has a compression force deflection from about 2kPa to about 15kPa.
  • Feature set 4 A build unit with any of feature sets 1 to 3, further comprising the compressible element and wherein the compressible element is a foam-type element.
  • Feature set 5 A build unit with any of feature sets 1 to 4, further comprising a plurality of stacked compressible elements.
  • Feature set 6 A build unit with any of feature sets 1 to 5, further comprising the compressible element and wherein the compressible element comprises a non-uniform geometry.
  • Feature set 7 A build unit with any of feature sets 1 to 6, further comprising the compressible element and wherein the build unit is configured such that when the build platform is in its highest position, the compressible element is not to deform plastically.
  • Feature set 8 A build unit o with any of feature sets 1 to 7, further comprising the compressible element and wherein the compressible element is an inflatable membrane.
  • Feature set 9 A kit comprising: a cover plate to reduce the cross-section of an opening of a build chamber comprising a vertically-moveable build platform, wherein the build chamber has an open-topped object generation volume having a uniform cross-section; and
  • a compressible element to be placed between the cover plate and the build platform to reduce the object generation volume.
  • Feature set 10 A kit with feature set 9, wherein the cover plate is to be fixed to a wall from the build chamber.
  • Feature set 11 A kit with any of feature sets 9 or 10, wherein the compressible element has a compression force deflection from about 2kPa to 15kPa.
  • Feature set 12 A three-dimensional printer comprising: a powder distribution module to form layers of build material in a build chamber;
  • the build chamber defining an open-topped object generation volume having a uniform cross-section, comprising a build platform to move vertically within the object generating module, and wherein the build chamber comprises fixation elements to:
  • Feature set 13 A three-dimensional printer with feature set 12, further comprising a controller to: receive data corresponding to a set of objects to be generated; determine if the dimensions of the set of objects can be generated in a reduced object generation volume and where it is so determined indicate to a user to install the cover plate and the compressible element corresponding to the reduced object generation volume; control the powder distribution module to form successive layers of build material in the reduced object generation volume; and control the fusing module to selectively solidify portions of the formed layers to generate the set of objects.
  • Feature set 14 A three-dimensional printer with feature set 12, further comprising a controller to: receive data corresponding to a set of objects to be generated; determine if the cover plate is present in the build chamber and where it is so determined, determine if the set of objects to be generated can be generated in a reduced object generation volume corresponding to the cover plate; control the powder distribution module to form successive layers of build material in the reduced object generation volume; and control the fusing module to selectively solidify portions of the formed layers to generate the set of objects.
  • Feature set 15 A three-dimensional printer with any of feature sets 12 to 14, wherein the controller is to: determine a lowest usable position of the build platform based on the reduced object generation volume; and prevent the build platform to move vertically beyond the lowest usable position.

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

Abstract

Selon un mode de réalisation représentatif, l'invention concerne une unité de construction. L'unité de construction comporte une chambre de construction définissant un volume de génération d'objets à partie supérieure ouverte ayant une section transversale uniforme. L'unité de construction comporte également une plateforme de construction pour se déplacer verticalement à l'intérieur du volume de génération d'objets. L'unité de construction sert à recevoir de manière fixe une plaque de couverture pour réduire la section transversale d'une ouverture de la chambre de construction et pour recevoir un élément compressible à placer entre la plaque de couverture et la plateforme de construction pour réduire le volume de génération d'objet.
PCT/US2019/015731 2019-01-29 2019-01-29 Éléments compressibles WO2020159485A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130270746A1 (en) * 2010-08-20 2013-10-17 Zydex Pty Ltd Apparatus and method for making an object
WO2017054859A1 (fr) * 2015-09-30 2017-04-06 Hewlett-Packard Development Company, L.P. Récipients pour matériau de construction
WO2018186837A1 (fr) * 2017-04-04 2018-10-11 Hewlett-Packard Development Company, L.P. Formation de couches d'un matériau de construction
WO2018194614A1 (fr) * 2017-04-20 2018-10-25 Hewlett-Packard Development Company, L.P. Imprimante 3d et module de construction

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130270746A1 (en) * 2010-08-20 2013-10-17 Zydex Pty Ltd Apparatus and method for making an object
WO2017054859A1 (fr) * 2015-09-30 2017-04-06 Hewlett-Packard Development Company, L.P. Récipients pour matériau de construction
WO2018186837A1 (fr) * 2017-04-04 2018-10-11 Hewlett-Packard Development Company, L.P. Formation de couches d'un matériau de construction
WO2018194614A1 (fr) * 2017-04-20 2018-10-25 Hewlett-Packard Development Company, L.P. Imprimante 3d et module de construction

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