Skillful three-dimensional printing

Patent metadata

Field	Value
Publication number	US-10071422-B2
Application number	US-201615374318-A
Country	US
Kind code	B2
Filing date	Dec 9, 2016
Priority date	Dec 10, 2015
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

The present disclosure various apparatuses, and systems for 3D printing. The present disclosure provides three-dimensional (3D) printing methods, apparatuses, software and systems for a step and repeat energy irradiation process; controlling material characteristics and/or deformation of the 3D object; reducing deformation in a printed 3D object; and planarizing a material bed.

First claim

What is claimed is:

1. A method for printing a three-dimensional object, comprising:
(a) providing a material bed comprising a pre-transformed material, wherein the pre-transformed material comprises a solid, a semi-solid, or a liquid material, wherein the material bed comprises an exposed surface;
(b) planarizing the exposed surface by directing an excess of the pre-transformed material from the exposed surface disposed above a plane into an internal compartment of a material remover through a nozzle of the material remover, to form a planarized exposed surface, wherein the nozzle comprises an adjustable volume; and
(c) using an energy beam to transform the pre-transformed material in at least a portion of the planarized exposed surface to a transformed material, wherein the transformed material is at least a portion of the three-dimensional object.

2. The method of claim 1 , wherein the planarizing is in an absence of contact between the material remover and the exposed surface of the material bed.

3. The method of claim 1 , wherein the pre-transformed material is directed using an electrostatic force, a magnetic force, a gas flow, or any combination thereof.

4. The method of claim 3 , wherein the gas flow is generated using vacuum or compressed gas.

5. The method of claim 1 , wherein the adjustable volume is an internal volume of the nozzle.

6. The method of claim 1 , wherein the nozzle comprises at least one adjustable part.

7. The method of claim 1 , wherein the nozzle comprises a Venturi nozzle.

8. The method of claim 1 , wherein the adjustable volume is asymmetric.

9. The method of claim 1 , wherein the pre-transformed material is formed of at least one member selected from the group consisting of an elemental metal, a metal alloy, a ceramic, and an allotrope of elemental carbon.

10. The method of claim 1 , wherein the pre-transformed material in at least the portion of the planarized exposed surface is transformed to the transformed material upon fusing individual particles of the material bed.

11. The method of claim 1 , further comprising adjusting the nozzle to regulate a volume into which the pre-transformed material is directed from the material bed.

12. The method of claim 1 , further comprising adjusting the nozzle to regulate a rate at which the pre-transformed material is directed from the material bed into the nozzle.

13. The method of claim 1 , wherein the pre-transformed material is accumulated in the internal compartment at least in part by separating the pre-transformed material from a gas flow that is generated upon directing the pre-transformed material from the exposed surface through the nozzle of the material remover.

14. The method of claim 13 , wherein the separating is cyclonically separating.

15. The method of claim 1 , wherein the pre-transformed material comprises at least one member selected from the group consisting of an elemental metal, a metal alloy, a ceramic, an allotrope of elemental carbon, a polymer, and a resin.

16. The method of claim 1 , wherein the pre-transformed material comprises a particulate material.

17. The method of claim 1 , further comprising adjusting the adjustable volume of the nozzle.

18. The method of claim 1 , wherein the pre-transformed material is directed through the nozzle and accumulates in the internal compartment of the material remover.

19. The method of claim 1 , wherein a vertical cross-sectional area of the internal compartment is greater by at least three times a horizontal cross-sectional area of an opening of the nozzle.

20. The method of claim 1 , wherein (b) comprises (i) directing the pre-transformed material from the exposed surface through the nozzle of the material remover along a flow of gas, and (ii) accumulating at least a portion of the pre-transformed material in the internal compartment upon separation of the pre-transformed material from the flow of gas.

21. The method of claim 20 , wherein the at least the portion of the pre-transformed material accumulates in the internal compartment upon cyclonical separation of the pre-transformed material from the flow of gas.

22. The method of claim 1 , wherein the pre-transformed material is directed from the exposed surface into the internal compartment using an attractive force that is controlled to regulate a volume from which the pre-transformed material is attracted from the material bed into the nozzle.

23. The method of claim 1 , wherein the nozzle is an asymmetric nozzle.

Assignees

• Velo3D Inc

Inventors

• Buller Benyamin
• Milshtein Erel
• Brezoczky Thomas Blasius
• Murphree Zachary Ryan
• Christiansen Daniel
• Lappen Alan Rick

Classifications

• B29C64/307 Primary

  Handling of material to be used in additive manufacturing · CPC title

• B22F12/60 Primary

  Planarisation devices; Compression devices · CPC title

• B29C64/35

  Cleaning · CPC title

• B29C64/357

  Recycling · CPC title

• B22F12/70

  Gas flow means · CPC title